Motorized shutter assembly

ABSTRACT

In one aspect, a shutter assembly includes a shutter frame and a plurality of louvers supported by the frame. The shutter assembly also includes a louver drive assembly and a motor positioned within the frame. The motor is configured to rotationally drive a drive shaft extending within the frame. Additionally, the shutter assembly includes a clutch assembly rotationally coupled between the drive shaft and the louver drive assembly. The clutch assembly is configured to disengage or decouple the drive shaft from the louver drive assembly when a torque transmitted through the clutch assembly exceeds a given torque threshold.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based upon and claims the right of priority to U.S.Provisional Patent Application No. 62/439,527, filed on Dec. 28, 2016,the disclosure of which is hereby incorporated by reference herein inits entirety for all purposes.

FIELD OF THE INVENTION

The present subject matter relates generally to coverings forarchitectural structures and, more particularly, to a motorized shutterassembly for use as a covering for an architectural structure, such as awindow.

BACKGROUND OF THE INVENTION

Shutter assemblies typically include two or more shutter panelsconfigured to be installed within a frame relative to an architecturalstructure, such as a window. Each shutter panel includes a shutter frameand a plurality of louvers configured to rotate relative to the shutterframe. For instance, the ends of the louvers are often rotatably coupledto the shutter frame via louver pegs to allow the louvers to be rotatedrelative to the frame between a substantially vertical orientation and asubstantially horizontal orientation. Additionally, in many instances, atie bar may be secured to all or a portion of the louvers of eachshutter panel to couple the louvers to one another, thereby allowingsuch louvers to be rotated simultaneously relative to the adjacentshutter frame.

To enhance the functionality and usability of shutter assemblies,attempts have been made to integrate automatic louver drive systemswithin shutter assemblies that allow for the automatic adjustment of therotational orientation of the louvers. For example, louver drive systemshave been developed in the past that include multiple motors as well ascomplex gearbox arrangements associated with each motor. As a result,these conventional louver drive systems are often costly and quitedifficult to design and manufacture. In addition, due to the use ofmultiple motors and associated gearboxes, such louver drive systemssignificantly increase the overall weight of the associated shutterassembly and also reduce the available space for the louvers of theshutter assembly given the significant storage requirements for themotors/gearboxes.

Accordingly, an improved motorized shutter assembly would be welcomed inthe technology.

BRIEF DESCRIPTION OF THE INVENTION

Aspects and advantages of the present subject matter will be set forthin part in the following description, or may be obvious from thedescription, or may be learned through practice of the present subjectmatter.

In various aspects, the present subject matter is directed to a shutterassembly for use as a covering for an architectural structure, with theshutter assembly including a motorized drive system. Specifically, inseveral embodiments, the shutter assembly includes a motor configured todrive a primary drive shaft coupled to a louver drive assembly. Thelouver drive assembly may, in turn, be coupled to one or more drivenlouvers of the shutter assembly. Accordingly, by rotating the primarydrive shaft via the motor, rotational motion is transferred to eachdriven louver via the louver drive assembly to allow the rotationalorientation of the louvers to be automatically adjusted.

Additionally, in several embodiments, the shutter assembly includes oneor more clutch assemblies configured to disengage or decouple thelouvers from the motor when the rotational orientation of the louvers isbeing manually adjusted, thereby allowing the automatic louver drivesystem to be manually overridden when desired. For instance, in oneembodiment, a clutch assembly may be coupled between the primary driveshaft and the louver drive assembly. In such an embodiment, the clutchassembly is configured to disengage or decouple the louver driveassembly from the primary drive shaft, thereby allowing the drivenlouvers to be rotated freely without back-driving the motor.

Moreover, in accordance with aspects of the present subject matter, themotor of the disclosed drive system may be configured to drive thelouvers of one or more additional shutter panels positioned relative tothe shutter panel within which the motor is installed. For instance, inone embodiment, adjacent shutter panels include drive shafts thatterminate at or adjacent to an interface defined between the shutterpanels. In such an embodiment, the adjacent ends of the shafts may becoupled to each other at the interface to allow rotational motion fromone of the drive shafts to be transferred to the adjacent drive shaftacross the interface, thereby allowing the motor to drive the louvers ofthe adjacent shutter panels.

These and other features, aspects and advantages of the present subjectmatter will become better understood with reference to the followingdescription and appended claims. The accompanying drawings, which areincorporated in and constitute a part of this specification, illustrateembodiments of the present subject matter and, together with thedescription, serve to explain the principles of the present subjectmatter.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present subject matter, includingthe best mode thereof, directed to one of ordinary skill in the art, isset forth in the specification, which makes reference to the appendedfigures, in which:

FIG. 1 illustrates a perspective view of one illustrative embodiment ofa motorized shutter assembly configured for use as a covering for anarchitectural structure in accordance with aspects of the presentsubject matter, particularly illustrating the shutter panels in a closedposition relative to the adjacent architectural structure;

FIG. 2 illustrates a front view of the shutter assembly shown in FIG. 1,particularly illustrating the shutter panels in an open positionrelative to the adjacent architectural structure;

FIG. 3 illustrates a simplified front view of the shutter assembly shownin FIG. 1 with the frames of the shutter panels being shown in wireframeto allow various internal components of the shutter assembly to beviewed, particularly illustrating one illustrative embodiment of a drivesystem configured for use within the shutter assembly in accordance withaspects of the present subject matter;

FIG. 4 illustrates a perspective, assembled view of one illustrativeembodiment of a rack assembly suitable for use within the disclosedshutter assembly in accordance with aspects of the present subjectmatter;

FIG. 5 illustrates a perspective, exploded view of the rack assemblyshown in FIG. 4;

FIG. 6 illustrates a perspective, assembled view of another illustrativeembodiment of a rack assembly suitable for use within the disclosedshutter assembly in accordance with aspects of the present subjectmatter;

FIG. 7 illustrates a perspective, exploded view of the rack assemblyshown in FIG. 6;

FIG. 8 illustrates a perspective, assembled view of a furtherillustrative embodiment of a rack assembly suitable for use within thedisclosed shutter assembly in accordance with aspects of the presentsubject matter;

FIG. 9 illustrates a perspective, exploded view of the rack assemblyshown in FIG. 8;

FIG. 10 illustrates a perspective, assembled view of one illustrativeembodiment of a clutch assembly suitable for use within the disclosedshutter assembly in accordance with aspects of the present subjectmatter;

FIG. 11 illustrates a perspective, exploded view of the clutch assemblyshown in FIG. 10;

FIG. 12 illustrates a cross-sectional view of the clutch assembly shownin FIG. 10 taken about line XII-XII;

FIG. 13 illustrates a perspective view of a first clutch drive member ofthe clutch assembly shown in FIG. 11;

FIG. 14 illustrates a perspective view of a second clutch drive memberof the clutch assembly shown in FIG. 11;

FIG. 15 illustrates a perspective view of a clutch sleeve of the clutchassembly shown in FIG. 11;

FIG. 16 illustrates a perspective, assembled view of anotherillustrative embodiment of a clutch assembly suitable for use within thedisclosed shutter assembly in accordance with aspects of the presentsubject matter;

FIG. 17 illustrates a perspective, exploded view of the clutch assemblyshown in FIG. 16;

FIG. 18 illustrates a cross-sectional view of the clutch assembly shownin FIG. 16 taken about line XVIII-XVIII;

FIG. 19 illustrates a perspective view of a first clutch drive member ofthe clutch assembly shown in FIG. 17;

FIG. 20 illustrates a perspective view of a second clutch drive memberof the clutch assembly shown in FIG. 17;

FIG. 21 illustrates a perspective view of a clutch sleeve of the clutchassembly shown in FIG. 17;

FIG. 22 illustrates a perspective, assembled view of one illustrativeembodiment of a coupling assembly suitable for use within the disclosedshutter assembly in accordance with aspects of the present subjectmatter;

FIG. 23 illustrates a perspective, exploded view of the couplingassembly shown in FIG. 22;

FIG. 24 illustrates another perspective, exploded view of the couplingassembly shown in FIG. 22;

FIG. 25 illustrates a perspective view of a coupler of the couplingassembly shown in FIG. 22;

FIG. 26 illustrates a perspective, assembled view of anotherillustrative embodiment of a coupling assembly suitable for use withinthe disclosed shutter assembly in accordance with aspects of the presentsubject matter;

FIG. 27 illustrates a perspective, exploded view of the couplingassembly shown in FIG. 26;

FIG. 28 illustrates another perspective, exploded view of the couplingassembly shown in FIG. 26;

FIG. 29 illustrates a perspective view of a coupler of the couplingassembly shown in FIG. 26;

FIG. 30 illustrates a cross-sectional view of one embodiment of variousdrive system components installed within a shutter panel in accordancewith aspects of the present subject matter;

FIG. 31 illustrates a perspective view of one embodiment of variousdrive system components of a louver drive assembly installed within astile of a shutter panel in accordance with aspects of the presentsubject matter;

FIG. 32 illustrates a perspective view of one embodiment of a couplingassembly installed within a stile of a shutter panel in accordance withaspects of the present subject matter;

FIG. 33 illustrates a cross-sectional view of a portion of the couplingassembly shown in FIG. 32;

FIG. 34 illustrates a cross-sectional view of one embodiment of variousdrive system components installed within adjacent shutter panels inaccordance with aspects of the present subject matter;

FIG. 35 illustrates a simplified front view of another embodiment of theshutter assembly shown in FIG. 3 with the frames of the shutter panelsbeing shown in wireframe to allow various internal components of theshutter assembly to be viewed, particularly illustrating oneillustrative embodiment of a drive system configured for use within theshutter assembly in accordance with aspects of the present subjectmatter; and

FIG. 36 illustrates a simplified front view of a further embodiment ofthe shutter assembly shown in FIG. 3 with the frames of the shutterpanels being shown in wireframe to allow various internal components ofthe shutter assembly to be viewed, particularly illustrating oneillustrative embodiment of a drive system configured for use within theshutter assembly in accordance with aspects of the present subjectmatter.

DETAILED DESCRIPTION OF THE INVENTION

Reference now will be made in detail to embodiments of the presentsubject matter, one or more examples of which are illustrated in thedrawings. Each example is provided by way of explanation without intentto limit the broad concepts of the present subject matter. In fact, itwill be apparent to those skilled in the art that various modificationsand variations can be made in the present subject matter withoutdeparting from the scope or spirit of the present subject matter. Forinstance, features illustrated or described as part of one embodimentcan be used with another embodiment to yield a still further embodiment.Thus, it is intended that the present subject matter covers suchmodifications and variations as come within the scope of the appendedclaims and their equivalents.

In general, the present subject matter is directed to a shutter assemblyconfigured for use as a covering for an architectural structure, withthe shutter assembly including a motorized louver drive system.Specifically, in several embodiments, the motorized louver drive systemincludes a motor configured to adjust the rotational orientation of thelouvers within the shutter assembly. As such, when the user activatesthe motor, the motor may be used to drive the louvers without anyfurther manual interaction from the user.

In one embodiment, a louver drive assembly is installed within a shutterframe of the shutter assembly (e.g., within a stile of the shutterframe) that is configured to be coupled to a primary drive shaft coupledto the motor. In such an embodiment, the louver drive assembly may becoupled to one or more driven louvers of the shutter assembly.Accordingly, rotation of the primary drive shaft via the motor may betransferred through the louver drive assembly to each driven louver,thereby allowing the orientation of the louvers within the shutterassembly to be adjusted.

Additionally, the shutter assembly also includes one or more clutchassemblies configured to disengage or decouple the louvers from themotor. Specifically, in several embodiments, each clutch assembly may beconfigured to decouple its associated louver(s) from the motor when therotational orientation of such louver(s) is being adjusted manually(e.g., adjustment without the use of a motor or other mechanizeddevice). As such, the automatic louver drive system may be manuallyoverridden when a user of the shutter assembly desires to adjust one ormore of the louvers manually. In addition, such decoupling of thelouvers from the motor may be desirable to prevent back-driving of themotor during manual adjustment, which may reduce the potential fordamage to the motor.

In one embodiment, each clutch assembly includes one or more torquetransfer members that provide a selective coupling (e.g., a rotationalcoupling) between separate input and output members or portions of theclutch assembly (e.g., first and second clutch drive members of theclutch assembly). In such an embodiment, the torque transfer member(s)may be configured to transfer torque between the input and outputmembers when the torque being transmitted through the clutch assembly isless than a given torque threshold (e.g., when the louvers are beingdrive by a motor). However, when the torque being transmitted throughthe clutch assembly exceeds the associated torque threshold (e.g.,during manual operation), the torque transfer member(s) may allow theinput and output members to be decoupled or disengaged from each other.

In one embodiment, a first portion of the coupling formed by the torquetransfer member(s) of the clutch assembly may be configured toselectively engage the input member while a second portion of thecoupling formed by the torque transfer member(s) may be configured toselectively engage the output member. In such an embodiment, the firstand second portions of the coupling may be configured to engage theinput and output members, respectively, when the torque beingtransmitted through the clutch assembly is below the torque threshold.However, when the torque being transmitted through the clutch assemblyexceeds the torque threshold, one of the first portion or the secondportion of the coupling may be configured to disengage from itsrespective input/output member when the rotational direction of thetorque input into the clutch assembly is in a first direction while theother of the first portion or the second portion of the coupling may beconfigured to disengage from its respective input/output member when therotational direction of the torque input into the clutch assembly is ina second, opposite direction.

In one embodiment, the first and second portions of the coupling formedby the torque transfer member(s) of the clutch assembly correspond toseparate coiled sections of a single clutch spring or respective coiledsections of separate clutch springs. In such an embodiment, the coiledsections may be counter-wrapped or wound in opposite directions relativeto each other. As such, when the torque being transmitted through theclutch assembly exceeds the torque threshold, one of the coiled sectionsmay be configured to tighten around its respective input/output memberwhile the other coiled section may be configured to loosen relative toits respective input/output member depending on the rotational directionof the torque. The loosened coiled section may, thus, be allowed to sliprelative to or otherwise decouple from its respective input/outputmember, thereby permitting the input member to be decoupled ordisengaged from the output member.

Moreover, in several embodiments, the shutter assembly includes two ormore shutter panels configured to be installed adjacent to one anotherwithin a frame positioned relative to the architectural structure. Insuch embodiments, the motor of the louver drive system may be configuredto drive all of the louvers of the shutter assembly, including both thelouvers of the shutter panel within which the motor is installed and thelouvers of any other adjacent shutter panels. For instance, in oneembodiment, adjacent shutter panels include drive shafts that terminateat or adjacent to an interface defined between the shutter panels. Insuch an embodiment, the adjacent ends of the shafts may be coupled toeach other at the interface to allow rotational motion from one of thedrive shafts to be transferred to the adjacent drive shaft across theinterface, thereby allowing a single motor to drive the louvers of theadjacent shutter panels.

In one embodiment, the adjacent ends of the drive shafts of adjacentshutter panels are coupled to each other via mating coupling assembliespositioned at the shaft ends. In such an embodiment, each couplingassembly includes one or more engagement features configured to engagecorresponding engagement features of the mating coupling assembly. Forinstance, each coupling assembly may include axially extending ribsconfigured to engage corresponding ribs of the mating coupling assembly.As such, when one of the drive shafts is rotated, torque may betransferred across the interface defined between the shutter panels tothe adjacent drive via the engagement provided between the matingcoupling assemblies. In addition, the engagement feature(s) of thecoupling assemblies may be configured to align with each other when oneof the drive shafts is rotated relative to the other, thereby permittingtorque to be transferred across the interface even when the couplingassemblies are initially misaligned.

In a particular aspect of the present subject matter, a shutter assemblyincludes a shutter frame, a plurality of louvers supported by theshutter frame, and a louver drive assembly positioned within the shutterframe, with the louver drive assembly being rotationally coupled to atleast one driven louver of the plurality of louvers. Additionally, theshutter assembly includes a motor positioned within the shutter frame,with the motor being configured to rotationally drive a drive shaftextending lengthwise within the shutter frame. Moreover, the shutterassembly includes a clutch assembly rotationally coupled between thedrive shaft and the louver drive assembly. The clutch assembly includesa first clutch drive member, a second clutch drive member, and first andsecond torque transfer members coupled to each other to provide arotational coupling between the first and second clutch drive members,with first torque transfer member configured to be selectively engagedwith the first clutch drive member, and the second torque transfermember configured to be selectively engaged with the second clutch drivemember. In such an embodiment, when a torque transmitted through theclutch assembly exceeds a torque threshold (e.g., such as when a louveris moved manually by a user with or without the motor), one of the firsttorque transfer member or the second torque transfer member isconfigured to disengage from a respective clutch drive member of thefirst and second clutch drive members to decouple the first clutch drivemember from the second clutch drive member.

Additionally, in one embodiment, when the torque transmitted through theclutch assembly is less than the torque threshold, the first and secondtorque transfer members are engaged with the first and second clutchdrive members, respectively, to allow the torque to be transmittedbetween the first and second clutch drive members. In one embodiment, aminimum torque required to rotationally drive the louvers may be lessthan the torque threshold such that the torque is transmitted betweenthe first and second clutch drive members when the motor is beingoperated to rotationally drive the louver drive assembly withoutexternal input to the louvers.

Moreover, in one embodiment, the torque transmitted through the clutchassembly is configured to exceed the torque threshold when the louversare being manually rotated.

Further, in one embodiment, the first torque transfer member correspondsto a first clutch spring and the second torque transfer membercorresponds to a second clutch spring. In such an embodiment, the firstclutch spring may be configured to be selectively engaged with a firstspring support surface of the first clutch drive member, and the secondclutch spring may be configured to be selectively engaged with a secondspring support surface of the second clutch drive member. For example,when the torque transmitted through the clutch assembly exceeds thetorque threshold, the first clutch spring may be configured to tightenaround the first spring support surface, and the second clutch springmay be configured to loosen relative to the second spring supportsurface when the torque is transmitted through the clutch assembly in afirst direction, thereby allowing the second clutch spring to sliprelative to the second clutch drive member. Additionally, the firstclutch spring may be configured to loosen relative to the first springsupport surface, and the second clutch spring may be configured totighten around the second spring support surface when the torque istransmitted through the clutch assembly in an opposite, seconddirection, thereby allowing the first clutch spring to slip relative tothe first clutch drive member.

Additionally, in one embodiment, the first and second clutch springs arecoupled to each other via a clutch sleeve such that the first and secondclutch springs and the clutch sleeve collectively form the rotationalcoupling between the first and second clutch drive members. In such anembodiment, the first clutch spring may include, for example, both afirst coiled section extending around a portion of the first clutchdrive member, and a first spring tang extending outwardly from the firstcoiled section. Similarly, the second clutch spring may include, forinstance, both a second coiled section extending around a portion of thesecond clutch drive member, and a second spring tang extending outwardlyfrom the second coiled section.

Moreover, in one embodiment, the first and second spring tangs areconfigured to be coupled to the clutch sleeve. For example, the clutchsleeve may include an outer wall and a spring engagement portionextending radially inwardly from the outer wall. In addition, the springengagement portion may define both a first engagement slot for receivingthe first spring tang and a second engagement slot for receiving thesecond spring tang.

Further, in one embodiment, the louver drive assembly includes a driverack assembly rotationally engaged with the clutch assembly and at leastone driven rack assembly rotationally engaged with a louver drive postassociated with the driven louver(s). In such an embodiment, the driverack assembly and the driven rack assembly may be operatively coupled toeach other via a pair of drive bars extending lengthwise within theshutter frame. Moreover, in one embodiment, the drive rack assemblyincludes a rack gear and a pair of geared racks configured to mesh withthe rack gear, with the rack gear being configured to rotationallyengage the second clutch drive member of the clutch assembly.

Additionally, in one embodiment, the shutter frame includes a top rail,a bottom rail, and first and second stiles extending between the top andbottom rails.

Further, in one embodiment, the motor and the clutch assembly are bothpositioned within one of the bottom rail or the top rail.

In another aspect, the present subject matter is directed to a clutchassembly for use within a motorized shutter, with the motorized shutterincluding a motor configured to rotationally drive a drive shaft and alouver drive assembly rotationally coupled to a plurality of louvers ofthe motorized shutter.

In one embodiment, the clutch assembly includes a clutch housing and afirst clutch drive member configured to be at least partially receivedwithin the clutch housing, with first clutch drive member beingconfigured to rotationally engage the drive shaft. The clutch assemblyalso includes a second clutch drive member configured to be at leastpartially received within the clutch housing, with the clutch drivemember being configured to rotationally engage a component of the louverdrive assembly. Additionally, the clutch assembly includes a firsttorque transfer member configured to be selectively engaged with thefirst clutch drive member, and a second torque transfer member coupledconfigured to be selectively engaged with the second clutch drivemember, with the first and second torque transfer members being coupledto each other to provide a rotational coupling between the first andsecond clutch drive members. Moreover, when a torque transmitted throughthe clutch assembly exceeds a torque threshold, one of the first torquetransfer member or the second torque transfer member is configured torotationally disengage from a respective clutch drive member of thefirst and second clutch drive members to decouple the first clutch drivemember from the second clutch drive member.

Additionally, in one embodiment, when the torque transmitted through theclutch assembly is less than the torque threshold, the first and secondtorque transfer members are engaged with the first and second clutchdrive members, respectively, to allow the torque to be transmittedbetween the first and second clutch drive members.

Moreover, in one embodiment, the first torque transfer membercorresponds to a first clutch spring and the second torque transfermember corresponds to a second clutch spring. Further, in oneembodiment, the torque threshold corresponds to a slippage torque of thefirst and second clutch springs.

In a further aspect, the present subject matter is directed to a shutterassembly including a first shutter panel having a first shutter frameand a first drive shaft extending within the first shutter frame. Theshutter assembly also includes a second shutter panel having a secondshutter frame configured to extend adjacent to the first shutter frameat a panel-to-panel interface defined between the first and secondshutter panels, with the second shutter panel including a second driveshaft extending within the second shutter frame and being axiallyaligned with the first drive shaft. Additionally, the shutter assemblyalso includes a motor rotationally coupled to the first drive shaft.Moreover, the shutter assembly includes a first coupling assemblycoupled to an end of the first drive shaft, with the first couplingassembly including a plurality of first engagement ribs extendingaxially towards the second shutter panel at the panel-to-panelinterface. Further, the shutter assembly includes a second couplingassembly coupled to an end of the second drive shaft, with the secondcoupling assembly including a plurality of second engagement ribsextending axially towards the first shutter panel at the panel-to-panelinterface. The first engagement ribs are configured to engage the secondengagement ribs such that rotational motion of the first drive shaft istransferred to the second drive shaft across the panel-to-panelinterface.

In one embodiment, the first engagement ribs extend axially from an endwall of the first coupling assembly and are spaced apartcircumferentially in an annular array such that a circumferential gap isdefined between each adjacent pair of the first engagement ribs.Additionally, in one embodiment, each of the first engagement ribsdefines a radial height, with the radial height being greater than acircumferential width of the circumferential gap defined between eachadjacent pair of the first engagement ribs.

Moreover, in one embodiment, the first coupling assembly includes acoupling base rotationally engaged with the first drive shaft, and aspring-loaded coupler configured to be received within the couplingbase, with the first engagement ribs extending outwardly from an endwall of the spring-loaded coupler.

Further, in one embodiment, the coupling base defines a shaft openingconfigured to receive the first drive shaft.

Additionally, in one embodiment, the spring-loaded coupler defines aplurality of recesses configured to receive corresponding engagementfeatures of the coupling base. In one embodiment, at least one of therecesses corresponds to a closed-end recess and at least one of therecesses corresponds to an open-end recess. In such an embodiment, atleast one of the engagement features of the coupling base may beconfigured to serve as a stop for limiting the axial movement of thespring-loaded coupler relative to the coupling base.

Moreover, in one embodiment, the spring-loaded coupler includes aplurality of flanges extending outwardly from its outer perimeter, andthe coupling base defines a plurality of channels configured to receivethe flanges when the coupler is received within the coupling base.

Further, in one embodiment, the coupling base includes a stop providedin association with at least one of the channels to limit axial movementof the coupler relative to the coupling base.

Additionally, in one embodiment, one or more springs are positionedbetween the coupling base and the spring-loaded coupler. The spring(s)is configured to bias the coupler outwardly relative to a wall of thecoupling base.

In another aspect, the present subject matter is directed to a shutterassembly including a first shutter panel having a first shutter frameincluding a first bottom rail and a first top rail. The first shutterpanel further includes a first drive shaft extending within one of thefirst top rail or the first bottom rail. The shutter assembly alsoincludes a second shutter panel having a second shutter frame configuredto extend adjacent to the first shutter frame at a panel-to-panelinterface defined between the first and second shutter panels. Thesecond shutter panel includes a second drive shaft extending within thesecond shutter frame that is axially aligned with the first drive shaft.Additionally, the shutter assembly includes a motor rotatably coupled tothe first drive shaft, a first coupling assembly coupled to an end ofthe first drive shaft, and a second coupling assembly coupled to an endof the second drive shaft. The first and second coupling assemblies areconfigured to engage each other at the panel-to-panel interface suchthat rotational motion of the first drive shaft is transferred to thesecond drive shaft across the panel-to-panel interface.

In one embodiment, the first coupling member includes a plurality offirst engagement ribs extending axially towards the second couplingmember at the panel-to-panel interface. Additionally, the secondcoupling member includes a plurality of second engagement ribs extendingaxially towards the first coupling member at the panel-to-panelinterface. The first engagement ribs are configured to rotationallyengage the second engagement ribs to allow rotational motion to betransferred from the first drive shaft to the second drive shaft.

In yet another aspect, the present subject matter is directed to ashutter assembly including a shutter frame, a plurality of louverssupported by the shutter frame, and a louver drive assembly positionedwithin the shutter frame, with the louver drive assembly being coupledto at least one driven louver of the plurality of louvers. The shutterassembly also includes a motor positioned relative to the shutter frame,with the motor being configured to drive a drive shaft extendinglengthwise within the shutter frame. Additionally, the shutter assemblyincludes a clutch assembly coupled between the drive shaft and thelouver drive assembly. The clutch assembly includes an input clutchportion, an output clutch portion, and a coupling provided between theinput and output clutch portion. A first portion of the coupling isconfigured to be selectively engaged with the input clutch portion and asecond portion of the coupling is configured to be selectively engagedwith the output clutch portion. Moreover, when a torque transmittedthrough the clutch assembly exceeds a torque threshold, one of the firstportion or the second portion of the rotational coupling is configuredto disengage from a respective clutch portion of the input and outputclutch portions to decouple the input clutch portion from the outputclutch portion.

In one embodiment, the input clutch portion corresponds to a firstclutch drive member coupled to the drive shaft, and the output clutchportion corresponds to a second clutch drive member coupled to thelouver drive assembly. Additionally, in one embodiment, the firstportion corresponds to a first coiled spring section of the rotationalcoupling, and the second portion corresponds to a second coiled springsection of the rotational coupling.

In a further aspect, the present subject matter is directed to a shutterassembly including a shutter frame, a plurality of louvers supported bythe shutter frame, and a louver drive assembly positioned within theshutter frame, with the louver drive assembly being coupled to at leastone driven louver of the plurality of louvers. The shutter assembly alsoincludes a motor positioned within the shutter frame, with the motorbeing configured to drive a drive shaft extending lengthwise within theshutter frame. Additionally, the shutter assembly includes a clutchassembly coupled between the drive shaft and the louver drive assembly.The clutch assembly includes an input clutch member, an output clutchmember, and a coupling provided between the input and output clutchmembers. A first portion of the coupling is configured to be selectivelyengaged with the input clutch member and a second portion of thecoupling is configured to be selectively engaged with the output clutchmember. When a torque transmitted through the clutch assembly exceeds atorque threshold, the first portion of the rotational coupling isconfigured to disengage from the input member when a rotationaldirection of the torque is in a first direction, and the second portionof the rotational coupling is configured to disengage from the outputmember when the rotational direction of the torque is in a seconddirection opposite the first direction.

In one embodiment, the input clutch portion corresponds to a firstclutch drive member coupled to the drive shaft, and the output clutchportion corresponds to a second clutch drive member coupled to thelouver drive assembly.

Additionally, in one embodiment, the first portion corresponds to afirst coiled spring section of the rotational coupling and the secondportion corresponds to a second coiled spring section of the rotationalcoupling.

It should be appreciated that various embodiments of differentcomponents, sub-assemblies, and/or systems will be described herein asbeing configured for use within the disclosed shutter assembly. Incertain instances, specific embodiments of one or more components,sub-assemblies, and/or systems of the shutter assembly will be describedin the context of other embodiments of one or more of the components,sub-assemblies, and/or systems of the shutter assembly. Suchdescriptions are simply provided for exemplary purposes and should notbe interpreted as limiting the scope of the present subject matter. Ingeneral, the various embodiments of the components, sub-assemblies,and/or systems described herein may be used, assembled, and/or combinedin any suitable manner to produce a shutter assembly having one or moreof the advantageous features of the present subject matter.

It should also be appreciated that, although present subject matter isgenerally described herein with reference to specific embodiments, theconfiguration of each component described herein may be independent ofthe configuration of every other component described herein and thevarious components may generally be structured to engage and/or interactwith one another in any suitable manner consistent with the disclosureprovided herein.

Referring now to FIGS. 1-3, differing views of one example of anembodiment of a shutter assembly 100 configured for use as a coveringfor an architectural structure 102 (FIG. 2) are illustrated inaccordance with aspects of the present subject matter. As shown, theshutter assembly 100 generally includes one or more shutter panels 104A,104B configured to be coupled to an outer frame 106 (e.g., a framedefining or associated with the adjacent architectural structure 102).For instance, in the illustrated embodiment, the shutter assembly 100includes both a first shutter panel 104A and a second shutter panel 104Bcoupled to outer frame 106. However, in other embodiments, the shutterassembly 100 may only include a single shutter panel installed relativeto the outer frame 106 or three or more shutter panels installedrelative to the outer frame 106. As shown in FIGS. 1-3, the shutterpanels 104A, 104B may, in one embodiment, be pivotably coupled to theouter frame 106 (e.g., via hinges 108 (FIG. 1)) to allow the shutterpanels 104A, 104B to be moved between closed (FIG. 1) and open positions(FIG. 2) relative to the adjacent architectural structure 102. Forexample, as particularly shown in FIG. 1, the shutter panels 104A, 104Bmay be moved to the closed position to cover the adjacent architecturalstructure 102. In such closed position, shutter panels 104A, 104B maygenerally be positioned in a generally planar configuration (e.g., byextending in a plane oriented substantially parallel to the adjacentarchitectural structure 102), with ends of shutter panels 104A, 104Bextending directly adjacent to each other along the height of the panels104A, 104B such that a vertically extending panel-to-panel interface 110(FIGS. 1 and 3) is defined between the shutter panels 104A, 104B.Additionally, as shown in FIG. 2, the shutter panels 104A, 104B may bemoved to the open position to expose the architectural structure 102.For instance, the panels 104A, 104B may be pivoted outwardly away fromthe architectural structure 102 so that each panel 104A, 104B has anangled orientation relative to the plane defined by at least a portionof the architectural structure 102.

In general, each shutter panel 104A, 104B includes a shutter frame 112A,112B and a plurality of louvers 114 configured to rotate relative to theassociated frame 112A, 112B. As shown in FIGS. 1-3, a first shutterframe 112A of the first shutter panel 104A may have a generallyrectangular shape defined by a first frame-side stile 116, a firstpanel-side stile 118, and top and bottom rails 120, 122 extendinghorizontally between the vertically extending stiles 116, 118.Similarly, as shown in FIGS. 1-3, a second shutter frame 112B of thesecond shutter panel 104B may have a generally rectangular shape definedby a second frame-side stile 124, a second panel-side stile 126, and topand bottom rails 128, 130 extending horizontally between the verticallyextending stiles 124, 126. As particularly shown in FIG. 1, when theshutter panels 104A, 104B are at their closed position relative to thearchitectural structure 102, the first panel-side stile 118 of the firstshutter frame 112A may be configured to extend vertically adjacent tothe second panel-side stile 126 of the second shutter frame 112B alongthe panel-to-panel interface 110 defined between the panels 104A, 104B.

It should be appreciated that the adjacent panel-side stiles 118, 126 ofthe shutter frames 112A, 112B may be configured to contact each other atthe panel-to-panel interface 110, or may be spaced apart from each othersuch that a gap is defined between the adjacent shutter frames 112A,112B at the panel-to-panel interface 110. Additionally, as will bedescribed below, each shutter panel 104A, 104B may, in one embodiment,include a coupling assembly 132A, 132B (FIGS. 2 and 3) positioned at thepanel-to-panel interface 110 that is configured to engage acorresponding coupling member 132A, 132B of the adjacent shutter panel104A, 104B to allow the louvers 114 of the shutter frames 104A, 104B tobe driven via a common motorized drive system 134 of shutter assembly100.

As indicated above, each shutter panel 104A, 104B also includes aplurality of louvers 114 configured to be rotated relative to itsassociated shutter frame 112A, 112B. For example, as shown in theillustrated embodiment, the first shutter panel 104A includes aplurality of louvers 114 extending horizontally between the verticalstiles 116, 118 of the first shutter frame 112A. Similarly, the secondshutter panel 104B includes a plurality of louvers 114 extendinghorizontally between the vertical stiles 124, 126 of the second shutterframe 112B.

As is generally understood, each louver 114 may be configured to rotateabout its longitudinal axis relative to the adjacent shutter frame 112A,112B approximately 180 degrees to vary the degree to which thearchitectural structure 102 may be viewed through the shutter panels104A, 104B when the panels 104A, 104B are at their closed positions. Forinstance, the louvers 114 may be rotated to a substantially horizontalorientation (e.g., a fully open position as shown in FIG. 1) to allowmaximum exposure to the architectural structure 102 through shutterpanels 104A, 104B. Similarly, the louvers 114 may be rotatedapproximately 90 degrees in one direction or the other from thesubstantially horizontal orientation to a substantially verticalorientation (e.g., a fully closed position as shown in FIG. 2) to blockthe view through the shutter panels 104A, 104B. For instance, when attheir substantially vertical orientation, adjacent louvers 114 mayvertically overlap each other at their top and bottom ends to fullyblock the view through the shutter panels 104A, 104B.

In several embodiments, one or more groups or sections of the variouslouvers 114 may be coupled together in a manner that allows the louvers114 to rotate simultaneously or otherwise in unison with one another.For example, as shown in FIG. 1, each shutter panel 104A, 104B includesa tie bar 136 that is configured to couple all of the louvers 114included within such panel 104A, 104B to one another. As such, by movingthe tie bar 136 for a given shutter panel up or down, all of the louvers114 within such panel may be rotated about their respective longitudinalaxes. Similarly, due to the connection provided by each tie bar 136,rotation of one of the louvers 114 within a given shutter panel mayresult in corresponding rotation of the remainder of the louvers 114included within such panel. For example, when one of the louvers 114 ofthe second shutter panel 104B is rotated about its axis, the associatedtie bar 136 may result in the remainder of the louvers 114 within thesecond shutter panel 104B being rotated about their longitudinal axes.

In several embodiments, one or more of the louvers 114 of each shutterpanel 104A, 104B corresponds to a driven louver 114A, 114B (e.g., alouver that is being directly driven by a component of the drive system134), with the remainder of the louvers 114 in such panel correspondingto non-driven louvers (e.g., a louver that is being indirectly drivenvia its connection to a driven louver). For instance, as shown in FIG.3, the first shutter panel 104A includes three driven louvers 114A whilethe second shutter panel 104B similarly includes three driven louvers114B. However, in other embodiments, each shutter panel 104A, 104B mayinclude fewer than three driven louvers or greater than the three drivenlouvers. As will be described in greater detail below, each drivenlouver 114A, 114B may be coupled to a motor of the drive system 134 toallow such louver to be driven about its longitudinal axis. As a result,by rotating a given driven louver 114A, 114B, the remainder of thelouvers 114 in the corresponding shutter panel 104A, 104B may be rotatedabout their longitudinal axes.

It should be appreciated that the tie bars 136 of the shutter assembly100 may generally be configured to be positioned at any suitablelocation relative to the louvers 114. For instance, in the illustratedembodiment, the tie bars 136 are positioned at the ends of the louvers114 located adjacent to the frame-side stiles 116, 124 along the frontside of the shutter panels 104A, 104B (i.e., the side facing away fromthe architectural structure 102). However, in other embodiments, the tiebars 136 may be positioned at any other suitable location along thefront side of the shutter panels 104A, 104B, such as by positioning thetie bars 136 at a central location along the louvers 114 or bypositioning the tie bars 136 at the ends of the louvers 114 locatedadjacent to the panel-side stiles 118, 126. Similarly, in anotherembodiment, the tie bars 136 may be positioned along the rear side ofthe shutter panels 104A, 104B (i.e., the side facing towards thearchitectural structure 102). It should also be appreciated that, inalternative embodiments, the louvers 114 contained within each shutterpanel 104A, 104B may be coupled to one another using any other suitablemeans that allows for each section of louvers 114 to rotate in unison(e.g., an internal coupling obviating the need for an external coupling,such as the tie bars 136).

As indicated above, in several embodiments, the disclosed shutterassembly 100 also includes a motorized drive system 134 for driving thedriven louver(s) 114A, 114B, of each shutter panel 104A, 104B.Specifically, as shown in FIG. 3, the drive system 134 includes a motorassembly 138 having a single electric motor 140 configured to be coupledto each driven louver 114A, 114B. For example, as particularly shown inFIG. 3, the motor 140 is, in one embodiment, positioned within thebottom rail 122, 130 of one of the shutter panels 104A, 104B, such asthe bottom rail 122 of the first shutter panel 104A. However, in otherembodiments, the motor 140 may be positioned at any other suitablelocation within the shutter assembly 100, such as within the top rail120, 128 of one of the shutter panels 104A, 104B.

It should be appreciated that the motor 140 may generally be powered viaany suitable power source. For example, in one embodiment, one or morebatteries may be installed within the shutter assembly 100 to supplypower to the motor 140, such as by installing a battery pack 142 withinthe bottom rail 122 of the first shutter frame 112A at a locationadjacent to the motor assembly 138. Alternatively, the motor 140 may beconfigured to receive power from any other suitable power source, suchas by hardwiring the motor 140 to an external power source (e.g., a 120volt electrical circuit).

It should also be appreciated that the operation of the motor 140 may,in several embodiments, be controlled automatically via a suitablecontroller or other electronic circuit. For instance, as shown in FIG.3, the motor assembly 138 also includes a motor controller 144communicatively coupled to the motor 140. In one embodiment, the motorcontroller 140 may incorporate or may otherwise be associated with acommunications module for wirelessly receiving motor control signals. Insuch an embodiment, the operation of the motor 140 may be remotelycontrolled via a separate control device (e.g., a remote control device,such as an RF-based or IR-based remote control device) configured tocommunicate with the motor controller 140 via the communications module.

Additionally, in several embodiments the motor 140 may be coupled toeach driven louver 114A, 114B via a louver drive assembly 146A, 146Binstalled within each shutter frame 112A, 112B. Specifically, as shownin FIG. 3, a first louver drive assembly 146A is installed within theone of the stiles 116, 118 of the first shutter panel 104A, such as thefirst panel-side stile 118, for transferring rotational motion from themotor 140 to the driven louvers 114A of the first shutter panel 104A. Inone embodiment, the first louver drive assembly 146A may correspond to arack and gear-type drive arrangement. For instance, as shown in FIG. 3,the first louver drive assembly 146A includes a first drive rackassembly 148A coupled to a first drive shaft 150A driven by the motor140, and a first pair of drive bars 154 extending lengthwise along theheight of the corresponding stile 118. Additionally, in one embodiment,the first louver drive assembly 146A includes a first driven rackassembly 152A coupled to the drive bars 154 at the location of eachdriven louver 114A of the first shutter panel 104A. Each driven rackassembly 152A may, in turn, be coupled to the associated driven louver114A. For instance, as shown in FIG. 3, each driven rack assembly 152Amay be coupled to a louver peg or post 158A extending outwardly from theadjacent end (or endcap) of the driven louver 114A.

Moreover, in several embodiments, a second louver drive assembly 146B isinstalled within the one of the stiles 124, 126 of the second shutterpanel 104B, such as the second panel-side stile 126, for transferringrotational motion from the motor 140 to the driven louvers 114B of thesecond shutter panel 104B. Similar to the first louver drive assembly146A, the second louver drive assembly 146B may, in one embodiment,correspond to a rack and gear-type drive arrangement. For instance, asshown in the illustrated embodiment, the second louver drive assembly146B includes a second drive rack assembly 148B, a second pair of drivebars 156 extending lengthwise along the height of the correspondingstile 126, and a separate second driven rack assembly 152B coupled tothe drive bars 156 at the location of each driven louver 114B of thesecond shutter panel 104B, with each second driven rack assembly 152Bbeing, in turn, coupled to the associated driven louver 114B. Forinstance, as shown in FIG. 3, each driven rack assembly 152B may becoupled to a louver peg or post 158B extending outwardly from theadjacent end (or endcap) of the driven louver 114B. It should beappreciated that each driven louver 114A, 114B is associated with acorresponding driven assembly (e.g., rack assembly 152A, 152B). Forexample, in the illustrated embodiment, each shutter panel 104A, 104Bincludes three driven louvers 114A, 114B, and, thus, each louver driveassembly 146A, 146B similarly includes three driven rack assemblies152A, 152B. However, in other embodiments, the disclosed shutterassembly 100 may include any suitable number of driven louvers 114A,114B and associated driven rack assemblies 152A, 152B.

In accordance with one embodiment of the present subject matter, thesecond drive rack assembly 148A may be configured to be driven by asecond drive shaft 150B coupled to the first drive shaft 150A via a pairof coupling assemblies 132A, 132B installed at the panel-to-panelinterface 110 defined between the shutter panels 104A, 104B.Specifically, as shown in FIG. 3, the first drive shaft 150A may becoupled to a first coupling assembly 132A installed within the firstpanel-side stile 118 of the first shutter panel 104A at thepanel-to-panel interface 110 and the second drive shaft 150B may becoupled to a second coupling assembly 132B installed within the secondpanel-side stile 126 of the second shutter panel 104B at thepanel-to-panel interface 110, with the coupling assemblies 132A, 132Bbeing engageable with each other at the interface 110 to allowrotational motion of the first drive shaft 150A to be transferred to thesecond drive shaft 150B.

Thus, in the illustrated embodiment, by driving the first drive rackassembly 148A via rotation of the first drive shaft 150A, the firstdrive rack assembly 148A may cause the first pair of drive bars 154 totranslate relative to each other along the height of the firstpanel-side stile 118. Such relative translation of the drive bars 154may, in turn, drive each first driven rack assembly 152A, therebycausing rotation of the corresponding driven louvers 114A via theassociated louver posts 158A. Additionally, simultaneous with drivingthe first drive rack assembly 148A, rotational motion from the firstdrive shaft 150A may be transferred to the second drive shaft 150B viathe engagement of the coupling assemblies 132A, 132B to drive the seconddrive rack assembly 148B and, thus, cause the associated drive bars 156to be translated relative to each other. The translation of the drivebars 156 may, in turn, drive each second driven rack assembly 152B,thereby causing rotation of the corresponding driven louvers 114B viathe associated louver posts 158B. Various aspects of one or moreillustrative embodiments of a rack assembly 148, 152 suitable for usewithin the disclosed shutter assembly 100 will be described in greaterdetail below with reference to FIGS. 4-9. Similarly, various aspects ofone or more illustrative embodiments of a coupling assembly 132 suitablefor use within the disclosed shutter assembly 100 will be described ingreater detail below with reference to FIGS. 22-29.

It should be appreciated that, in other embodiments, the louver driveassemblies 146A, 146B may include any other suitable drive arrangementfor transferring the rotational motion or torque from the motor 140 tothe driven louvers 114A, 114B of each shutter panel 104A, 104B. Forinstance, in one embodiment, the rack assemblies 148A, 148B, 152A, 152Bmay be replaced by gearboxes and a secondary drive shaft may beinstalled along the length of each corresponding stile 118, 126 thatextends through the associated gearboxes. In such an embodiment,rotation of the first and second drive shafts 150A, 150B may betransferred from the gearbox coupled directly to each drive shaft 150A,150B (e.g., the gearboxes replacing the drive rack assemblies 148A,148B) to the secondary shaft to drive the other gearboxes (e.g., thegearboxes replacing the driven rack assemblies 152A, 152B), which, inturn, may drive the driven louvers 114A, 114B.

Additionally, in several embodiments, the drive system 134 also includesone or more clutch assemblies associated with each shutter panel 104A,104B to permit the louvers 114 within each panel 104A, 104B to bedisengaged or decoupled from the motor 156, thereby allowing foradjustment of the rotational orientation of the louvers 114 manually(e.g., adjustment without the use of a motor or other mechanized device,such as when the user simply grasps a louver 114 to adjust itsposition). Specifically, as shown in FIG. 3, in one embodiment, thedisclosed shutter assembly 100 includes a first clutch assembly 160Apositioned within the bottom rail 122 of the first shutter panel 104Aand a second clutch assembly 160B positioned within the bottom rail 130of the second shutter panel 104B. However, in alternative embodiments,the clutch assemblies 160A, 160B may be positioned at any other suitablelocation within each respective shutter frame 112A, 112B, such as withineach panel-side stile 118, 126. As will be described in greater detailbelow, the first clutch assembly 104A may be operatively coupled betweenthe first drive shaft 150A and the first drive rack assembly 148A toallow the first louver drive assembly 146A to be disengaged or decoupledfrom the first drive shaft 150A. Similarly, the second clutch assembly160B may be operatively coupled between the second drive shaft 150B andthe second drive rack assembly 148B to allow the second louver driveassembly 146B to be disengaged or decoupled from the second drive shaft150B.

By including the clutch assemblies 160A, 160B within the disclosedshutter assembly 100, a user of the shutter assembly 100 may manuallyoverride the drive system 134 to allow for manual adjustment of theposition of the louvers 114. For instance, in the illustratedembodiment, a user may grasp one of the louvers 114 of the first shutterpanel 104A (e.g., one of the driven louvers 114A or any of thenon-driven louvers 114) or may grasp the associated tie bar 136 toadjust the orientation of all of the louvers 114 within such shutterpanel 104A manually. As the user begins to rotate the louvers 114manually, the first clutch assembly 160A may allow the first louverdrive assembly 146A to be disengaged from the first drive shaft 150A,thereby permitting the louvers 114 of the first shutter panel 104A to berotated freely independent of the motor 140 as well as the louvers 114associated with the second shutter panel 104B. Similarly, with manualrotation of the louvers 114 associated with the second shutter panel104B, the second clutch assembly 160B may function similarly to decouplethe second louver drive assembly 146A from the second drive shaft 150B,thereby allowing the louvers 114 of the second shutter panel 104B to berotated freely independent of the motor 140 as well as the louvers 114associated with the first shutter panel 104A.

Referring now to FIGS. 4 and 5, respective assembled and exploded viewsof one illustrative embodiment of a rack assembly 148, 152 suitable foruse within the disclosed shutter assembly 100 are illustrated inaccordance with aspects of the present subject matter. It should beappreciated that the rack assembly 148, 152 may, in one embodiment,illustrate aspects of one or more of the rack assemblies described abovewith reference to FIG. 3, such as one of the drive rack assemblies 148A,148B and/or one of the driven rack assemblies 152A, 152B.

As indicated above, the disclosed rack assemblies may generally beconfigured to permit rotational motion to be converted to lineartranslation of the associated drive bars 154, 156 (e.g., in the case ofthe drive rack assemblies 148A, 148B when being driven by the motor 140or in the case of the driven rack assemblies 152A, 152B when the user ismanually adjusting the position of the louvers 114) or to permit lineartranslation of the associated drive bars 154, 156 to be converted torotational motion (e.g., in the case of the driven rack assemblies 152A,152B when being driven by the motor 140 or in the case of the drive rackassemblies 148A, 148B when the user is manually adjusting the positionof the louvers 114). Thus, in general, it should be appreciated that thedisclosed rack assemblies may have any suitable configuration thatallows such components to function as described above.

As shown in FIGS. 4 and 5, in one embodiment, the rack assembly 148, 152includes a housing 200, a rack gear 202 configured to be rotationallysupported within the housing 200, and first and second geared racks 204,206 configured to mesh with the rack gear 202. In general, the housing200 may be configured to at least partially encase and/or support therack gear 202 and/or the associated gear racks 204, 206. Specifically,as shown in the illustrated embodiment, the housing 200 includes both afirst housing component 208 and a second housing component 210, with thefirst housing component 208 configured to be coupled to the secondhousing component 210. For instance, as shown in FIG. 5, each housingcomponent 208, 210 may define one or more fastener openings 212configured to receive suitable fasteners 214. Thus, when the housingcomponents 208, 210 are positioned relative to each other such that thefastener openings 212 of the first housing component 208 are alignedwith the fastener openings 212 of the second component 210, thefasteners 214 may be inserted through the aligned openings 212 to couplethe housing components 208, 210 to each other. Alternatively, thehousing components 208, 210 may be coupled to each other using any othersuitable attachment means, such as by using ultrasonic welding or bycreating a snap-fit between the housing components 208, 210.

As shown in FIG. 5, in one embodiment, the second housing component 210includes a base wall 216 and first and second sidewalls 218, 220extending outwardly from the base wall 216. Additionally, as shown inFIG. 5, the second housing component 210 includes first and secondraised projections 222, 224 extending outwardly from the base wall 216within a central portion of the second housing component 210. In oneembodiment, the first housing component 208 may be configured to beengaged against and/or supported by the top(s) of one or both of theprojections 222, 224 and/or the top(s) of one or both of the sidewalls218, 220 to set the desired spacing between the first housing component208 and the base wall 216 of the second housing component 210. Moreover,as shown in FIG. 5, a semi-circular or curved gear channel 226 isdefined between the first and second projections 222, 224 for receivingthe rack gear 202. In such an embodiment, corresponding openings 228 maybe defined through both the first housing component 208 and the basewall 216 of the second housing component 210 that are aligned with thegear channel 226 for receiving one or more component(s) of the discloseddrive system 134 (FIG. 3).

Additionally, in one embodiment, a translation channel 230 is definedalong both sides of the housing 200 for receiving the geared racks 204,206. Specifically, each translation channel 230 may be configured toextend in a widthwise direction (indicated by arrow W in FIG. 4) betweenthe base wall 216 of the second housing component 210 and the firsthousing component 208 and in a cross-wise direction (indicated by arrowX in FIG. 5) between the raised projections 222, 224 and correspondingchannel lips 236 defined along each outer side of the first and secondhousing components 208, 210. Moreover, as shown in FIG. 5, eachtranslation channel 230 may be configured to extend in a heightwisedirection (indicated by arrow H in FIG. 5) between an open end 240 (FIG.4) of the housing 200 and a structural support member 242 extendinginwardly from each of the sidewalls 218, 220 of the second housingcomponent 210. In such an embodiment, each geared rack 204, 206 may beconfigured to be translated relative to the housing 200 (e.g., viarotation of the rack gear 202) between the open end 240 of the housing200 and the support member 242.

As particularly shown in FIG. 5, the rack gear 202 of the rack assembly148, 152 includes outer gear teeth 244 configured to mesh with orotherwise engage corresponding rack teeth 246 provided on each gearedrack 204, 206. Thus, when the gear 202 and racks 204, 206 are installedwithin the housing 200 such that the outer gear teeth 244 mesh with therack teeth 246, rotation of the rack gear 202 relative to the housing200 may result in the geared racks 204, 206 being linearly translatedrelative to the housing 200 in opposite directions along each associatedtranslation channel 230 in the heightwise direction H. In such instance,the rack gear 202 may be rotated in a given direction until the end(s)of the geared racks 204, 206 reaches the gear 202 (or until the louvers114 contact one another in the closed position). Similarly, the rackgear 202 may be rotated in the opposite direction until the opposedend(s) of the geared racks 204, 206 reaches the gear 202 (or until thelouvers 114 contact one another in the closed position).

Additionally, as shown in FIG. 5, a gear opening 248 is defined throughthe rack gear 202 for receiving one or more components of the discloseddrive system 134. For instance, when the rack assembly 148, 152corresponds to one of the drive rack assemblies 148A, 148B, the gearopening 248 may be configured to receive a portion of the associatedclutch assembly 160A, 160B, thereby providing a mechanical connectionbetween the rack assembly 148A, 148B and the clutch assembly 160A, 160B.In such an embodiment, the gear opening 248 may be keyed or shaped inany suitable manner that allows the rack gear 202 to engage thecorresponding portion of the clutch assembly 160A, 160B. Specifically,as shown in FIG. 5, the gear opening 248 may, in one embodiment,correspond to a splined opening. In such an embodiment, the gear opening248 may be configured to receive a corresponding splined drive portion360 of a second clutch drive member 318 (FIG. 14) of the associatedclutch assembly 160A, 160B. Alternatively, when the rack assembly 148,152 corresponds to one of the driven rack assemblies 152A, 152B, thegear opening 248 may be configured to receive a portion of one of thelouver drive posts 158A, 158B (or a separate shaft coupling coupled tothe associated louver drive posts 158A, 158B), thereby providing amechanical connection between the rack assembly 152A, 152B and theassociated driven louver 114A, 114B. In such an embodiment, the gearopening 248 may be keyed or shaped in any suitable manner that allowsthe rack gear 202 to engage the corresponding portion of the louverdrive post 158A, 158B (or coupling). For instance, if the louver drivepost 158A, 158B defines one or more keyways (e.g., two opposed v-shapedkeyways), the gear opening 248 may be configured as a correspondingkeyed opening (e.g., gear opening 248′ shown in FIG. 31) to allow therack gear 202 to be coupled to the louver drive post 158A, 158B.

Moreover, in several embodiments, each geared rack 204, 206 may beconfigured to be coupled to one of the drive bars 154, 156 of theassociated louver drive assembly 146A 146B (FIG. 3) to allow the racks204, 206 and corresponding drive bars 154, 156 to be translated togetherrelative to the housing 200. For instance, as shown in phantom lines inFIG. 4, the drive bars 154, 156 are configured to be installed alongopposed sides of the housing 200. In such an embodiment, each gearedrack 204, 206 may be configured to be coupled to the adjacent drive bar154, 156 via any suitable means. For example, as shown in FIGS. 4 and 5,each geared rack 204, 206 includes a boss or projection 260 extendingoutwardly. In such an embodiment, when the associated drive bar 154,156and the housing 200 are placed side-by-side, the projection 260 may beinserted into (e.g., via a press-fit) a corresponding opening (notshown) defined in the drive bar 154, 156 to couple the drive bar 154,156 to the geared rack 204, 206.

By coupling the drive bars 154, 156 to the geared racks 204, 206, linearmotion may be transmitted from the gear racks 204, 206 to the drive bars154, 156 or vice versa, depending on the mode of operation of theshutter assembly 100. Specifically, when the shutter assembly 100 isbeing driven by the motor 140, the rack gear 202 of each drive rackassembly 148A, 148B may be rotated to translate the gear racks 204, 206of each drive rack assembly 148A, 148B and, thus, the drive bars 154,156 coupled to such geared racks 204, 206. The translation of the drivebars 154, 156 may then drive the geared racks 204, 206 of each drivenrack assembly 152A, 152B, which, in turn, rotates the rack gear 202 ofeach driven rack assembly 152A, 152B to drive the associated louverdrive posts 158A, 158B. Similarly, when the shutter assembly 100 isbeing manually operated, the rack gear 202 of each driven rack assembly152A, 152B may be rotated to translate the geared racks 204, 206 of eachdriven rack assembly 152A, 152B and, thus, the drive bars 154, 156coupled to such geared racks 204, 206. The linear translation of thedrive bars 154, 156 may then linearly drive the geared racks 204, 206 ofeach drive rack assembly 148A, 148B, which, in turn, results in rotationof the rack gear 202 of each drive rack assembly 148A, 148B.

It should be appreciated that, in some embodiments, the configuration ofthe drive rack assemblies 148A, 148B may be the same as theconfiguration of the driven rack assemblies 152A, 152B. For instance, inone embodiment, both the drive rack assemblies 148A, 148B and the drivenrack assemblies 152A, 152B may be configured in the manner shown inFIGS. 4 and 5. Alternatively, the configuration of the drive rackassemblies 148A, 148B may differ from the configuration of the drivenrack assemblies 152A, 152B. For instance, in one embodiment, the rackassembly 148, 152 shown in FIGS. 4 and 5 may correspond to the specificconfiguration for the drive rack assemblies 148A, 148B while the drivenrack assemblies 152A, 152B may be configured differently. For example,given their positioning, it may be desirable for the driven rackassemblies 152A, 152B to have a more compact design that provides forimproved assembly of the disclosed shutter assembly 100.

Referring now to FIGS. 6-9, several views of other embodiments of rackassemblies suitable for use within the disclosed shutter assembly 100are illustrated in accordance with aspects of the present subjectmatter. Specifically, FIGS. 6 and 7 illustrate respective assembled andexploded views of another illustrative embodiment of a rack assembly152′ that may correspond to one or more of the driven rack assemblies152A, 152B described above with reference to FIG. 3. Similarly, FIGS. 8and 9 illustrate respective assembled and exploded views of anotherillustrative embodiment of a rack assembly 148′ that may correspond toone or more of the drive rack assemblies 148A, 148B described above withreference to FIG. 3. It should be appreciated that, although the rackassembly 152′ shown in FIGS. 6 and 7 will be described herein as beingused as one of the driven rack assemblies, the rack assembly 152′ mayalso be used as one of the drive rack assemblies 148A, 148B.Additionally, although the rack assembly 148′ shown in FIGS. 8 and 9will be described herein as being used as one of the drive rackassemblies, the rack assembly 148′ may also be used as one of the drivenrack assemblies 152A, 152B.

In general, the rack assemblies 152′, 148′ shown in FIGS. 6-9 and theirassociated components are configured similar to the various componentsof the rack assembly 148, 152 described above. As such, the componentsor features of each rack assembly 152′, 148′ that are the same orsimilar to corresponding components or features of the rack assembly148, 152 described above with reference to FIGS. 4 and 5 will bedesignated by the same reference character with an apostrophe (′) added.Additionally, when a given component or feature of either rack assembly152′, 148′ is configured to generally perform the same function as thecorresponding component or feature of the rack assembly 148, 152described above with reference to FIGS. 4 and 5, a less detaileddescription of such component/feature will be provided with reference toFIGS. 6-9 for the sake of brevity.

As shown in FIGS. 6-9, in one embodiment, each rack assembly 152′, 148′includes a housing 200′, a rack gear 202′ configured to be rotationallysupported within the housing 200′, and first and second geared racks204′, 206′ configured to mesh with the rack gear 202′. In general, thehousing 200′ for each rack assembly 152′, 148′ may be configured similarto the housing 200 described above with reference to FIGS. 4 and 5. Forinstance, as shown in the illustrated embodiments, each housing 200′includes both a first housing component 208′ and a second housingcomponent 210′, with the first housing component 208′ configured to becoupled to the second housing component 210′ (e.g., via a snap-fit or byusing mechanical fasteners). As shown in FIGS. 7 and 9, in oneembodiment, each first housing component 208′ includes a first base wall215′ and each second housing component 210′ includes a base wall 216′.Additionally, as shown in FIGS. 7 and 9, each first housing component208′ includes a first raised projection 222′ extending outwardly fromthe first base wall 215′ and each second housing component 210 includesa second raised projection 224′ extending outwardly from the second basewall 216. Similar to the embodiment described above, when the housingcomponents 208′, 210′ are assembled together, a semi-circular or curvedgear channel (not shown) may be defined between the first and secondprojections 222′, 224′ for receiving the rack gear 202′. In such anembodiment, corresponding openings 228′ may be defined through both thefirst and second base walls 215′, 216′ that are aligned with the gearchannel for receiving one or more component(s) of the disclosed drivesystem 134 (FIG. 3).

In one embodiment, the first housing component 208′ of the rack assembly152′ shown in FIGS. 6 and 7 may slightly differ in construction from thefirst housing component 208′ of the rack assembly 148′ shown in FIGS. 8and 9. For example, as shown in FIGS. 8 and 9, the outer side of thefirst base wall 215′ of the rack assembly 148′ is generally planar.However, as shown in FIGS. 6 and 7, a spacer element 229′ extends fromthe outer side of the first base wall 215′ of the rack assembly 152′ atthe location of the opening 228′ defined through the first housingcomponent 208′. In one embodiment, the spacer element 229′ may functionto ensure that the rack assembly 152′ is installed at the appropriatelocation within the shutter assembly 100. For instance, when the rackassembly 152′ corresponds to one of the driven rack assemblies 152A,152B, the spacer element 229′ may function to ensure that the rackassembly 152′ is properly installed within the associated panel-sidestile 118, 126, such as by ensuring that the rack assembly 152′ isproperly spaced apart from one of the walls of the stile 118, 126.

Moreover, a translation channel 230′ (FIGS. 6 and 8) may be definedalong both sides of each housing 200′ for receiving the associatedgeared racks 204′, 206′. Specifically, each translation channel 230′ maybe configured to extend in a widthwise direction (indicated by arrow W′in FIGS. 6 and 8) between the first and second base walls 215′, 216′ ofeach housing 200′ and in a cross-wise direction (indicated by arrow X′in FIGS. 7 and 9) between the raised projections 222′, 224′ andcorresponding channel lips 236′ defined along each outer side of theassociated first and second housing components 208′, 210′. Moreover, asshown in FIGS. 7 and 9, each translation channel 230′ may be configuredto extend in a heightwise direction (indicated by arrow H′ in FIGS. 7and 9) between the opposed ends of the housing 200.

As particularly shown in FIGS. 7 and 9, the rack gear 202′ of each rackassembly 152′ includes outer gear teeth 244′ configured to mesh with orotherwise engage corresponding rack teeth 246′ provided on each gearedrack 204′, 206′. Thus, when the gear 202′ and racks 204′, 206′ areinstalled within each housing 200′ such that the outer gear teeth 244′mesh with the rack teeth 246′, rotation of the rack gear 202′ relativeto the housing 200′ may result in the geared racks 204′, 206′ beinglinearly translated relative to the housing 200′ in opposite directionsalong each associated translation channel 230′. Additionally, as shownin FIGS. 7 and 9, a gear opening 248′ is defined through the rack gear202′ for receiving one or more components of the disclosed drive system134. As indicated above, the gear opening 248′ may be keyed or shaped inany suitable manner that allows the rack gear 202′ to engage acorresponding portion of the shutter assembly 100. For instance, asshown in FIGS. 8 and 9, when the rack assembly 148′ corresponds to oneof the drive rack assemblies 148A, 148B, the gear opening 248′ may beconfigured to receive a portion of the associated clutch assembly 160A,160B, thereby providing a mechanical connection between the rackassembly 148′ and the clutch assembly 160A, 160B. In such an embodiment,the gear opening 248′ may be keyed or shaped in any suitable manner thatallows the rack gear 202′ to engage the corresponding portion of theclutch assembly 160A, 160B, such as by defining a splined openingconfigured to receive a corresponding splined drive portion 360 of asecond clutch drive member 318 of the associated clutch assembly 160A,160B (as described below with reference to FIG. 31). Similarly, as shownin FIGS. 6 and 7, when the rack assembly 152′ corresponds to one of thedriven rack assemblies 152A, 152B, the gear opening 248′ may beconfigured to receive a portion of one of the louver drive posts 158A,158B (or a separate shaft coupling coupled to the associated louverdrive posts 158A, 158B), thereby providing a mechanical connectionbetween the rack assembly 152′ and the associated driven louver 114A,114B. In such an embodiment, the gear opening 248′ may be keyed orshaped in any suitable manner that allows the rack gear 202′ to engagethe corresponding portion of the louver drive post 158A, 158B (orcoupling). For instance, if the louver drive post 158A, 158B defines oneor more keyways (e.g., two opposed v-shaped keyways), the gear opening248′ may be configured as a corresponding keyed opening (e.g., gearopening 248′ shown in FIG. 31) to allow the rack gear 202′ to be coupledto the louver drive post 158A, 158B.

Moreover, similar to the embodiment described above, each geared rack204′, 206′ may be configured to be coupled to one of the drive bars 154,156 of the associated louver drive assembly 146A 146B (FIG. 3) to allowthe racks 204′, 206′ and corresponding drive bars 154, 156 to besimultaneously translated relative to the housing 200′. For example, asshown in FIGS. 6-9, each geared rack 204′, 206′ may include an outwardlyextending boss or projection 260′. In such an embodiment, when theassociated drive bar 154,156 and the housing 200′ are placedside-by-side, the projection 260′ may be inserted into (e.g., via apress-fit) a corresponding opening (not shown) defined in the drive bar154, 156 to couple the drive bar 154, 156 to the geared rack 204′, 206′.

Referring now to FIGS. 10-15, several views of one illustrativeembodiment of a clutch assembly 160 and related components suitable foruse within the disclosed shutter assembly 100 are illustrated inaccordance with aspects of the present subject matter. It should beappreciated that the clutch assembly 160 may, in one embodiment,illustrate aspects of the first clutch assembly 160A and/or the secondclutch assembly 160B described above with reference to FIG. 3.

As indicated above with reference to FIG. 3, each clutch assembly 160A,160B may be configured to provide selective engagement of its associateddrive shaft 150A, 150B of the drive system 134 with the correspondinglouver drive assembly 146A, 146B, thereby allowing the louvers 114 to bemanually rotated by the user, when desired. For instance, in severalembodiments, the first clutch assembly 160A may be configured totransfer motion from the first drive shaft 150A to the first louverdrive assembly 146A when the motor 140 is being used to drive thelouvers 114. However, when the louvers 114 are being manually rotated,the first clutch assembly 160A may be configured to decouple the firstdrive rack assembly 148A from the first drive shaft 150A, therebypreventing torque from the first louver drive assembly 146A from beingtransferred through the clutch assembly 160A to the drive shaft 150A(and, thus, the motor 140).

As shown in the illustrated embodiment, the clutch assembly 160 includesa clutch housing 300 configured to at least partially encase the variousinternal components of the clutch assembly 160. In one embodiment, theclutch housing 300 includes both a housing member 302 extending axiallybetween a first end 304 and a second end 306 and a clutch cover 308configured to be coupled to the first end 304 of the housing member 302.As particularly shown in FIG. 12, when the clutch cover 308 is coupledto the first end 304 of the housing member 302, a cylindrically-shaped,open volume 310 may be defined between the cover 308 and the second end306 of the housing member 302 for receiving the internal components ofthe clutch assembly 160. It should be appreciated that cover 308 may beconfigured to be coupled to the housing member 302 using any suitablemeans. For instance, as shown in FIG. 11, both the cover 308 and thehousing member 302 may be configured to define corresponding openings312 configured to receive fasteners 314 for coupling the cover 308 tothe housing member 302. Alternatively, the cover 308 may be coupled tothe housing member 320 using any other suitable means, such as byultrasonic welding or by creating a snap-fit between the cover 308 andthe housing member 320. Additionally, as shown in FIG. 11, the housingmember 302 and the cover 308 may each define an axial opening 315 forreceiving one or more drive-related components of the drive system 134.Moreover, as shown in FIG. 10, the housing member 302 may include, forexample, a mounting arm 317 configured to provide structure for couplingthe clutch housing 300 to a portion of the shutter panel 104A, 104Bwithin which it is being installed.

In several embodiments, the clutch assembly 160 also includes first andsecond clutch drive members 316, 318 configured to serve as the inputand output components or members of the clutch assembly 160.Specifically, in one embodiment, the first clutch drive member 316 isconfigured to rotationally engage the corresponding drive shaft 150A,150B of the drive system 134 to allow rotational motion or torque fromthe motor 140 to be transferred to the clutch assembly 160.Additionally, in one embodiment, the second clutch drive member 318 isconfigured to rotationally engage a component of the correspondinglouver drive assembly 146A, 146B (e.g., one of the drive rack assemblies148A, 148B) to allow rotational motion or torque to be transferredbetween the clutch assembly 160 and such louver drive assembly 146A,146B. As such, when the motor 140 is being used to adjust theorientation of the louvers 114, the first clutch drive member 316corresponds to the input portion or member of the clutch assembly 160while the second clutch drive member 318 corresponds to the outputportion or member of the clutch assembly 160. However, as will bedescribed below, during manual operation of the shutter assembly 100,the second clutch drive member 318 may correspond to the input memberfor the clutch assembly 160.

Moreover, in several embodiments, the clutch assembly 160 also includesone or more torque transfer members for transferring torque between thefirst and second clutch drive members 316, 318 and for allowing suchcomponents 316, 318 to be decoupled from each other when the torquetransmitted through the clutch assembly 160 exceeds a given torquethreshold. Specifically, as shown in the illustrated embodiment, theclutch assembly includes, for example, first and second clutch springs320, 322 configured to be installed on the first and second clutch drivemembers 316, 318, respectively, and a clutch sleeve 324 configured toreceive portions of the clutch drive members 316, 318 and/or the springs320, 322. As will be described in greater detail below, the engagementof the clutch springs 320, 322 and the clutch sleeve 324 forms aconnection or coupling (e.g., a rotational coupling) between the clutchdrive members 316, 318 that allows torque to be transferred from thefirst clutch drive member 316 (e.g., via the associated drive shaft150A, 150B) to the second clutch drive member 318 when the torque isbelow a slippage torque associated with the clutch springs 320, 322,thereby allowing the motor 140 to drive the louvers 114 of the disclosedshutter assembly 100. However, when the torque exceeds the slippagetorque for the clutch springs 320, 322 (e.g., when the user is manuallyadjusting the position of the louvers 114), one of the clutch springs320, 322 may be configured to slip within the clutch assembly 160,thereby decoupling the clutch drive members 316, 318 from each otherand, thus, preventing torque from being transmitted from the secondclutch drive member 318 to the first clutch drive member 316.

As shown in FIGS. 11 and 13, the first clutch drive member 316 may beconfigured to extend axially between a first end 326 and a second end328 and may define a shaft opening 330 extending between its first andsecond ends 326, 328 for receiving the corresponding drive shaft 150A,150B of the drive system 134 (e.g., as shown in phantom lines in FIG.12). As indicated above, the drive shaft 150A, 150B may be configured todrive the first clutch drive member 316. Thus, in one embodiment, theshaft opening 330 may be keyed or may otherwise be configured such thatthe drive shaft 150A, 150B rotationally engages the first clutch drivemember 316 when the drive shaft 150A, 150B is received within the shaftopening 330. For instance, as shown in FIG. 13, a “V-shaped” key 332 maybe configured to extend into the opening 330 to allow the key 332 to bereceived within or otherwise engage a corresponding “V-shaped” keyway(not shown) defined in the drive shaft 150A, 150B.

Additionally, in several embodiments, the first clutch drive member 316includes a first spring support portion 334 and an elongated tubeportion 336, with the shaft opening 330 being defined through both thefirst spring support portion 334 and the elongated tube portion 336. Asshown in FIGS. 11 and 13, the first spring support portion 334 maygenerally extend axially between a tapered end 338 and a radial flange340 defined at or adjacent to the first end 326 of the first clutchdrive member 316. Similarly, the elongated tube portion 336 may extendaxially from the tapered end 338 of the first spring support portion 334to the second end 328 of the first clutch drive member 316.

In general, the first clutch spring 320 may be configured to beinstalled onto the first clutch drive member 316 such that the firstclutch spring 320 is positioned onto and wrapped around an outer springsupport surface 342 (FIG. 13) defined by the first spring supportportion 334 (e.g., the surface extending axially between the flange 340and the tapered end 338 of the first spring support portion 334).Specifically, in one embodiment, the first spring support portion 334and/or the first clutch spring 320 may be dimensioned such that aninterference fit is defined between the clutch spring 320 and the outerspring support surface 342 of the first spring support portion 334. Insuch an embodiment, the first clutch spring 320 may be configured to beinstalled onto the first clutch drive member 316 at its second end 328and then pushed axially over at least a portion of the tapered end 338of the first spring support portion 334 prior to being moved furtheronto the outer spring support surface 342 in the direction of the flange340 (e.g., by screwing the spring 320 around the outer spring supportsurface 342). In doing so, the reduced diameter of the tapered end 338of the first spring support portion 334 may assist in installing thespring 320 into the first spring support portion 334.

Additionally, as shown in FIGS. 11 and 14, the second clutch drivemember 318 may be configured to extend axially between a first end 344and a second end 346 and may define a pass-through opening 348 extendingbetween its first and second ends 344, 346 for receiving both theelongated tube portion 336 of the first clutch drive member 316 and thecorresponding drive shaft 150A, 150B of the drive system 134 (e.g., asshown in FIG. 12). Specifically, in several embodiments, thepass-through opening 348 may be dimensioned or otherwise configured toreceive the elongated tube portion 336 and the drive shaft 150A, 150Bwithout rotationally engaging such components. For instance, as shown inFIG. 12, an inner diameter 350 of the axial portion of the pass-throughopening 348 configured to receive the elongated tube portion 336 may begreater than a corresponding outer diameter 352 (FIG. 13) of theelongated tube portion 336 while the remainder of the pass-throughopening 348 may define a minimum inner diameter 354 that is greater thana corresponding outer diameter 356 of the drive shaft 150A, 150B. Assuch, when the clutch assembly 160 is in its disengaged state, thesecond clutch drive member 318 may be configured to rotate relative toboth the first clutch drive member 316 and the drive shaft 150A, 150B.

Moreover, in one embodiment, the second clutch drive member 318 includesa second spring support portion 358 and an elongated drive portion 360,with the pass-through opening 348 being defined through both the secondspring support portion 358 and the elongated drive portion 360. As shownin FIG. 14, the second spring support portion 358 may extend axiallybetween a tapered end 362 terminating at the first end 344 of the secondclutch drive member 318 and a radial flange 364. Similarly, theelongated drive portion 360 may extend axially from the radial flange364 to the second end 346 of the second clutch drive member 318.

In general, the second clutch spring 322 may be configured to beinstalled onto the second clutch drive member 318 such that the secondclutch spring 322 is positioned onto and wrapped around an outer springsupport surface 366 of the second spring support portion 358 (e.g., thesurface extending axially between the flange 364 and the tapered end 362of the second spring support portion 358). Specifically, in oneembodiment, the second spring support portion 358 and/or the secondclutch spring 322 may be dimensioned such that an interference fit isdefined between the clutch spring 322 and the outer spring supportsurface 366 of the second spring support portion 358. In such anembodiment, the second clutch spring 322 may be configured to beinstalled onto the second clutch drive member 318 at its first end 344and then pushed axially over at least a portion of the tapered end 362of the second spring support portion 358 prior to being moved furtheronto the outer spring support surface 366 in the direction of the flange364 (e.g., by screwing the spring 322 around the outer spring supportsurface 266). In doing so, the reduced diameter of the tapered end 362of the second spring support portion 358 may assist in installing thespring 322 into the second spring support portion 358.

Additionally, in several embodiments, the elongated drive portion 360 ofthe second clutch drive member 318 may be configured to extend outwardlyfrom the second end 306 of the housing member 302 (e.g., via the axialopening 315 defined through the housing member 302) to allow theelongated drive portion 360 to be received within and/or engage thecorresponding drive rack assembly 148A, 148B of the drive system 134.For instance, when assembling the clutch assembly 160, the elongateddrive portion 360 may be inserted through the axial opening 315 of thehousing member 302 until the flange 364 contacts the wall defined at thesecond end 306 of the housing member 302. Moreover, in severalembodiments, the elongated drive portion 360 may be keyed or otherwiseconfigured to engage the rack gear 202 of the corresponding drive rackassembly 148A, 148B. For example, as shown in FIG. 14, an axial sectionof the elongated drive portion 360 includes a plurality of radiallyoutwardly extending splines 368. In such an embodiment, the splinedsection of the elongated drive portion 360 may be configured to bereceived within and engage the corresponding splined opening 248, 248′of the rack gear 202, 202′ (FIGS. 5 and 9). As such, rotational motiontransmitted through the shutter's drive system 124 may be transferredfrom the second clutch drive member 318 to the drive rack assembly 148A,148B, and vice versa, as the shutter assembly 100 is operated via themotor 140 or manually.

Referring still to FIGS. 10-15, the clutch springs 320, 322 maygenerally correspond to coiled, torsional springs. As shown in FIG. 11,the first clutch spring 320 includes a first coiled section 370 and afirst spring tang 372 extending axially from the first coiled section370. Similarly, the second clutch spring 322 includes a second coiledsection 374 and a second spring tang 376 extending axially from thesecond coiled section 374. Additionally, in one embodiment, each coiledsection 370, 374 of the first and second clutch springs 320, 322 maydefine an enlarged end 378 at the axial end opposite the spring tang372, 376. Such an enlarged end 378 of each coiled section 370, 374, incombination with the tapered ends 338, 362 of the spring supportsections 334, 358 of the first and second clutch drive members 316, 318,may facilitate installing the first and second springs 320, 322 onto thefirst and second clutch drive members 316, 318, respectively.

As indicated above, in several embodiments, the clutch springs 320, 322and/or the spring support sections 334, 358 of the first and secondclutch drive members 316, 318 may be dimensioned and/or otherwiseconfigured to provide an interference fit between each spring 320, 322and its respective spring support portion 334, 358. In doing so, thedimension and/or configuration of such components may be selected sothat the specific fit defined between each spring 320, 322 and itsrespective spring support portion 334, 358 provides for the torquesprings 320, 322 to be associated with a desired slippage torque atwhich each spring 320, 322 may rotationally disengage from or otherwiseslip relative to the outer spring support surface 342, 366 of theadjacent spring support portion 334, 358. In such embodiments, thedesired slippage torque may be selected to be less than the outputtorque for the motor 140, but greater than the minimum torque requiredto operate or rotate the louvers 114 of each individual shutter panel104A, 104B. Thus, given that the slippage torque is greater than theminimum torque required to rotationally drive the louvers 114 of eachindividual shutter panel 104A, 104B, the torque actually beingtransferred through the clutch assembly 160 will be less than theslippage torque when the motor 140 is being used to drive the louvers114, thereby allowing both springs 320, 322 to be maintained inrotational engagement with the first and second clutch drive members316, 318. However, when the torque being transferred through the clutchassembly 160 is greater than the slippage torque (e.g., during manualoperation), at least one of the springs 320, 322 will slip relative tothe outer spring support surface 342, 366 of its adjacent spring supportportion 334, 358, thereby permitting the first clutch drive member 316to be disengaged or decoupled from the second clutch drive member 318.

Moreover, in one embodiment, the respective wires forming the coiledsections 370, 374 of the clutch springs 320, 322 may be wound inopposite directions. For instance, as shown in FIG. 11, the first clutchspring 320 is wound from the first spring tang 372 to its enlarged end378 in a clockwise direction. In contrast, the second clutch spring 322is wound from the second spring tang 376 to its enlarged end 378 in acounter-clockwise direction. As will be described below, suchcounter-wrapping or opposed winding directions of the clutch springs320, 322 may allow for one clutch spring to be tightened around itsadjacent spring support surface 342, 366 while the other clutch springis loosened relative to its adjacent spring support surface 342, 366when the torque being transferred through the clutch assembly 160exceeds the slippage torque for the springs 320, 322, thereby allowingthe loosened clutch spring to slip and, thus, decouple the first clutchdrive member 316 from the second clutch drive member 318.

As shown in FIGS. 11 and 15, the clutch sleeve 324 may generallycorrespond to an elongated member having a cylindrically-shaped outersleeve wall 380 extending axially between a first end 382 and a secondend 384. In general, the clutch sleeve 324 may be configured to encaseor receive portions of the first and second clutch drive members 316,318 when the clutch assembly 160 is assembled together. For instance, asshown in FIG. 12, as assembled, the first end 382 of the sleeve wall 380may be disposed adjacent to the flange 340 of the first clutch drivemember 316 and the second end 384 of the sleeve wall 380 may be disposedadjacent to the flange 364 of the second clutch drive member 318 so thatall or substantially all of the spring support portions 334, 358 of theclutch drive members 316, 318 are received within and surrounded by theclutch sleeve 324. In such an embodiment, each clutch spring 320, 322may be positioned directly between outer sleeve wall 380 and the outerspring support surface 342, 366 of its respective spring support portion334, 358. As a result, the outer sleeve wall 380 may serve to limit theradially outward expansion of the clutch springs 320, 322 when eitherspring is being loosened relative to its corresponding spring supportportion 334, 358 due to the torque transferred through the clutchassembly 160 exceeding the slippage torque of the springs 320, 322.

Additionally, the clutch sleeve 324 may be configured to engage eachtorsional spring 320, 322, thereby permitting torque to be transferredbetween the first and second clutch drive members 316, 318. Thus, inseveral embodiments, the clutch sleeve 324 includes a spring engagementportion 386 extending radially inwardly from the outer sleeve wall 380that is configured to engage the spring tang 372, 376 of each clutchspring 320, 322. As particularly shown in FIG. 15, the spring engagementportion 386 defines two or more engagement slots 388, 390, with eachspring tang 372, 376 being configured to be received within one of theengagement slots 388, 390 when the clutch assembly 160 is assembled. Inthe illustrated embodiment, the spring engagement portion 386 includesfour engagement slots 388, 390 (e.g., a first pair of slots 388configured to receive the first spring tang 372, and a second pair ofslots 390 configured to receive the second spring tang 376). Given thatthe insertion of the spring tangs 372, 376 into the clutch sleeve 324 isa blind assembly, the additional slots 388, 390 may reduce assembly timeby making it easier for the assembler to locate a slot 388, 390 forreceiving each spring tang 372, 374. However, in other embodiments, thespring engagement portion 386 may only define two engagement slots 388,390, one for each spring tang 370, 372. Regardless, by assembling theclutch assembly 160 so that each spring tang 370, 372 is received withinone of the engagement slots 388, 390, the clutch sleeve 324 may serve totransfer torque between the clutch springs 322, 324, thereby providing atorque coupling or bridge between the first and second clutch drivemembers 316, 318.

Moreover, in one embodiment, each engagement slot 388, 390 may be angledradially inwardly from the outer wall 380 to match the radial profile ofthe spring tang 370, 372 configured to be received within such slot 388,390. For instance, as shown in FIG. 12, the engagement slots 390configured to receive the second spring tang 376 may each define anangled surface 392 extending radially inwardly from the outer wall 380so that, when the second spring tang 376 is received in one of the slots390, the spring tang 376 is positioned between the angled surface 392 ofsuch slot 390 and the tapered end 362 of the spring support portion 358of the second clutch drive member 318. Similarly, as shown in FIG. 15,the engagement slots 388 configured to receive the first spring tang 372may also define an angled surface 394 extending radially inwardly fromthe outer wall 380 so that, when the first spring tang 372 is receivedin one of the slots 388, the spring tang 372 is positioned between theangled surface 394 of such slot 388 and the tapered end 338 of thespring support portion 334 of the first clutch drive member 316.

Referring now to FIGS. 16-21, several views of another illustrativeembodiment of a clutch assembly 160′ and related components suitable foruse within the disclosed shutter assembly 100 are illustrated inaccordance with aspects of the present subject matter. Specifically,FIGS. 16-21 generally correspond to similar views of the clutch assembly160′ as those shown above for clutch assembly 160 (i.e., in FIGS.10-15), except that the drive shaft 150A, 150B is shown in FIGS. 16-18.In general, the clutch assembly 160′ shown in FIGS. 16-21 and itsassociated components are configured similar to the various componentsof the clutch assembly 160 described above. As such, the components orfeatures of the clutch assembly 160′ that are the same or similar tocorresponding components or features of the clutch assembly 160described above with reference to FIGS. 10-15 will be designated by thesame reference character with an apostrophe (′) added. Additionally,when a given component or feature of the clutch assembly 160′ isconfigured to perform the same general function as the correspondingcomponent or feature of the clutch assembly 160 described above withreference to FIGS. 10-15, a less detailed description of suchcomponent/feature will be provided with reference to FIGS. 16-21 for thesake of brevity.

As shown in the illustrated embodiment, similar to the clutch assembly160 described above, the clutch assembly 160′ includes a clutch housing300′ having both a housing member 302′ extending axially between a firstend 304′ and a second end 306′ and a clutch cover 308′ configured to becoupled to the first end 304′ of the housing member 302′ such that acylindrically-shaped, open volume 310′ (FIG. 18) is defined between thecover 308′ and the second end 306′ of the housing member 302′ forreceiving the internal components of the clutch assembly 160′. Asparticularly shown in FIGS. 16 and 17, unlike the openings 312 andcorresponding fasteners 314 of the clutch housing 300 of FIGS. 10 and11, the clutch housing 300′ includes differing engagement or couplingfeatures for securing the housing member 302′ and the cover 308′ to eachother. Specifically, as shown in FIG. 17, the housing member 302′includes projections 311′ extending from its first end 304′ that areconfigured to snap into or otherwise engage corresponding engagementfeatures 313′ of the clutch cover 308′. However, it should beappreciated that, in other embodiments, the cover 308′ may be configuredto be coupled to the housing member 302′ using any other suitable means.Additionally, as shown in FIG. 17, the housing member 302′ and the cover308′ may each define an axial opening 315′ for receiving one or moredrive-related components of the drive system 134. Moreover, as shown inFIG. 16, the housing member 302′ may include, for example, a mountingarm 317′ configured to provide structure for coupling the clutch housing300′ to a portion of the shutter panel 104A, 104B within which it isbeing installed.

Additionally, the clutch assembly 160′ also includes first and secondclutch drive members 316′, 318′ configured to serve as the input andoutput components or members of the clutch assembly 160′, first andsecond clutch springs 320′, 322′ configured to be installed on the firstand second clutch drive members 316′, 318′, respectively, and a clutchsleeve 324′ configured to receive portions of the clutch drive members316′, 318′ and/or the springs 320′, 322′. In general, the first andsecond clutch drive members 316′, 318′, the first and second clutchsprings 320′, 322′, and the clutch sleeve 324′ may be configured tofunction the same as or similar to the corresponding components 316,318, 320, 322, 324 of the clutch assembly 160 described above withreferences to FIGS. 10-15. Thus, for example, the engagement of theclutch springs 320′, 322′ and the clutch sleeve 324′ may form aconnection or coupling (e.g., a rotational coupling) between the clutchdrive members 316′, 318′ that allows torque to be transferred from thefirst clutch drive member 316′ (e.g., via the associated drive shaft150A, 150B) to the second clutch drive member 318′ when the torque isbelow a slippage torque associated with the clutch springs 320′, 322′,thereby permitting the motor 140 to drive the louvers 114 of thedisclosed shutter assembly 100. However, when the torque exceeds theslippage torque for the clutch springs 320′, 322′ (e.g., when the useris manually adjusting the position of the louvers 114), one of theclutch springs 320′, 322′ may be configured to slip within the clutchassembly 160′, thereby decoupling the clutch drive members 316′, 318′from each other and, thus, preventing torque from being transmitted fromthe second clutch drive member 318′ to the first clutch drive member316′.

As shown in FIGS. 17 and 19, the first clutch drive member 316′ may beconfigured to extend axially between a first end 326′ and a second end328′ and may define a keyed shaft opening 330′ extending between itsfirst and second ends 326′, 328′ for receiving the corresponding driveshaft 150A, 150B of the drive system 134 (e.g., as shown in FIG. 18). Assuch, the drive shaft 150A, 150B may be configured to drive the firstclutch drive member 316′ (e.g., via a “V-shaped” key 332′ configured tobe received within or otherwise engage a corresponding “V-shaped” keyway(not shown) defined in the drive shaft 150A, 150B). Additionally, thefirst clutch drive member 316′ includes a first spring support portion334′ and an elongated tube portion 336′, with the shaft opening 330′being defined through both the first spring support portion 334′ and theelongated tube portion 336′. As shown in FIGS. 17 and 19, the firstspring support portion 334′ may generally extend axially between atapered end 338′ and a radial flange 340′ defined at or adjacent to thefirst end 326′ of the first clutch drive member 316′. Similarly, theelongated tube portion 336′ may extend axially from the tapered end 338′of the first spring support portion 334′ to the second end 328′ of thefirst clutch drive member 316′. Similar to the embodiment of the clutchassembly 160 described above, the first clutch spring 320′ may beconfigured to be installed onto the first clutch drive member 316′ suchthat the first clutch spring 320′ is positioned onto and wrapped aroundan outer spring support surface 342′ (FIG. 19) defined by the firstspring support portion 334′ (e.g., the surface extending axially betweenthe flange 340′ and the tapered end 338′ of the first spring supportportion 334′) to create an interference fit between the clutch spring320′ and the outer spring support surface 342′ of the first springsupport portion 334′.

Moreover, in one embodiment, the first clutch drive member 316′ mayinclude one or more additional features to facilitate rotationallyengaging the drive shaft 150A, 150B of the drive system 134. Forinstance, as particularly shown in FIG. 19, a set screw opening 343′ maybe defined through a portion of the first clutch drive member 316′(e.g., through the first spring support portion 334′) for receiving aset screw 345′ (FIG. 18). In such an embodiment, the set screw 345′ maybe screwed into the set screw opening 343′ and tightened into the driveshaft 150A, 150B to couple the first clutch drive member 316′ to thedraft shaft 150A, 150B, thereby preventing or minimizing rotational lashor play between such components. As shown in FIG. 18, in one embodiment,a groove or recess 347′ may be defined in the drive shaft 150A, 150B forreceiving the end of the set screw 345′, thereby providing a rotationallocking or engagement feature between the set screw 345′ and the driveshaft 150A, 150B.

Additionally, as shown in FIGS. 17 and 20, the second clutch drivemember 318′ may be configured to extend axially between a first end 344′and a second end 346′ and may define a pass-through opening 348′extending between its first and second ends 344′, 346′ for receivingboth the elongated tube portion 336′ of the first clutch drive member316′ and the corresponding drive shaft 150A′, 150B′ of the drive system134′ (e.g., as shown in FIG. 18). Specifically, in several embodiments,the pass-through opening 348′ may be dimensioned or otherwise configuredto receive the elongated tube portion 336′ and the drive shaft 150A,150B without rotationally engaging such components. For instance, asshown in FIG. 18, an inner diameter 350′ of the axial portion of thepass-through opening 348′ configured to receive the elongated tubeportion 336′ may be greater than a corresponding outer diameter 352′(FIG. 19) of the elongated tube portion 336′, while the remainder of thepass-through opening 348′ may define a minimum inner diameter 354′ thatis greater than a corresponding outer diameter 356′ of the drive shaft150A, 150B. Moreover, in one embodiment, the second clutch drive member318′ includes a second spring support portion 358′ and an elongateddrive portion 360′, with the pass-through opening 348′ being definedthrough both the second spring support portion 358′ and the elongateddrive portion 360′. As shown in FIG. 20, the second spring supportportion 358′ may extend axially between a tapered end 362′ terminatingat the first end 344′ of the second clutch drive member 318′ and aradial flange 364′. Similarly, the elongated drive portion 360′ mayextend axially from the radial flange 364′ to the second end 346′ of thesecond clutch drive member 318′. Similar to the embodiment of the clutchassembly 160 described above, the second clutch spring 322′ may beconfigured to be installed onto the second clutch drive member 318′ suchthat the second clutch spring 322′ is positioned onto and wrapped aroundan outer spring support surface 366′ of the second spring supportportion 358′ (e.g., the surface extending axially between the flange364′ and the tapered end 362 of the second spring support portion 358′)to create an interference fit between the clutch spring 322′ and theouter spring support surface 366′ of the second spring support portion358′.

Additionally, similar to the second clutch drive member 318 describedabove with reference to FIGS. 11 and 14, the elongated drive portion360′ of the second clutch drive member 318′ may be configured to extendoutwardly from the second end 306′ of the housing member 302′ (e.g., viathe axial opening 315′ defined through the housing member 302′) to allowthe elongated drive portion 360′ to be received within and/or engage thecorresponding drive rack assembly 148A′, 148B′ of the drive system 134.Moreover, as shown in FIG. 20, an axial section of the elongated driveportion 360 may include a plurality of radially outwardly extendingsplines 368′ for engaging the rack gear 202′ of the corresponding driverack assembly 148A′, 148B′. In such an embodiment, the splined sectionof the elongated drive portion 360′ may be configured to be receivedwithin and engage the corresponding splined opening 248′ of the rackgear 202′ (FIG. 9). As such, rotational motion transmitted through theshutter's drive system 124 may be transferred from the second clutchdrive member 318′ to the drive rack assembly 148A′, 148B′ and vice versaas the shutter assembly 100 is operated via the motor 140 or manually.

Referring still to FIGS. 16-21, the clutch springs 320′, 322′ maygenerally be configured the same as the clutch springs 320, 322described above. For instance, as shown in FIG. 17, the first clutchspring 320′ includes a first coiled section 370′ and a first spring tang372′ extending axially from the first coiled section 370′, while thesecond clutch spring 322′ includes a second coiled section 374′ and asecond spring tang 376′ extending axially from the second coiled section374′. Additionally, similar to the embodiment described above, eachcoiled section 370′, 374′ of the first and second clutch springs 320′,322′ may define an enlarged end 378′ at the axial end opposite thespring tang 372′, 376′ to facilitate installing the first and secondsprings 320′, 322′ onto the first and second clutch drive members 316′,318′, respectively.

Similar to the embodiment described above, the dimensions and/orconfiguration of the clutch springs 320′, 322′ and/or the first andsecond clutch drive members 316′, 318′ may be selected so that thespecific fit defined between each spring 320′, 322′ and its respectivespring support portion 334′, 358′ provides for the torque springs 320′,322′ to be associated with a desired slippage torque at which eachspring 320′, 322′ may rotationally disengage from or otherwise sliprelative to the outer spring support surface 342′, 366′ of the adjacentspring support portion 334′, 358′. For instance, as described above, thedesired slippage torque may be selected to be less than the outputtorque for the motor 140, but greater than the minimum torque requiredto operate or rotate the louvers 114 of each individual shutter panel104A, 104B. Moreover, in one embodiment, the respective wires formingthe coiled sections 370′, 374′ of the clutch springs 320′, 322′ may bewound in opposite directions to allow for one clutch spring to betightened around its adjacent spring support surface 342′, 366′ whilethe other clutch spring is loosened relative to its adjacent springsupport surface 342′, 366′ when the torque being transferred through theclutch assembly 160 exceeds the slippage torque for the springs 320′,322′, thereby permitting the loosened clutch spring to slip and, thus,decouple the first clutch drive member 316′ from the second clutch drivemember 318′.

As shown in FIGS. 17 and 21, the clutch sleeve 324′ may generallycorrespond to an elongated member having a cylindrically-shaped outersleeve wall 380′ extending axially between a first end 382′ and a secondend 384′. As shown in FIG. 18, the clutch sleeve 324′ may be configuredto encase or receive portions of the first and second clutch drivemembers 316′, 318′ when the clutch assembly 160 is assembled together sothat all or substantially all of the spring support portions 334′, 358′of the clutch drive members 316′, 318′ are received within andsurrounded by the clutch sleeve 324′. In such an embodiment, each clutchspring 320′, 322′ may be positioned directly between outer sleeve wall380′ and the outer spring support surface 342′, 366′ of its respectivespring support portion 334′, 358′, thereby allowing the outer sleevewall 380′ to limit the radially outward expansion of the clutch springs320′, 322′ when either spring is being loosened relative to itscorresponding spring support portion 334′, 358′.

Additionally, similar to the clutch sleeve 324 described above withreference to FIG. 15, the clutch sleeve 324′ includes a springengagement portion 386′ extending radially inwardly from the outersleeve wall 380′ that defines two or more engagement slots 388′, 390′configured to receive the spring tang 372′, 376′ of each clutch spring320′, 322′. As shown in FIG. 21, unlike the embodiment described above,the spring engagement portion 386′ includes four engagement slots 388′,390′ (e.g., four slots 388′ configured to receive the first spring tang372′ and four slots 390′ configured to receive the second spring tang376′). By assembling the clutch assembly 160′ so that each spring tang370′, 372′ is received within one of the engagement slots 388′, 390′,the clutch sleeve 324′ may serve to transfer torque between the clutchsprings 322′, 324′, thereby providing a torque coupling or bridgebetween the first and second clutch drive members 316′, 318′. Moreover,in one embodiment, each engagement slot 388′, 390′ may be angledradially inwardly from the outer wall 380′ to match the radial profileof the spring tang 370′, 372′ configured to be received within such slot388′, 390′. For instance, as shown in FIG. 18, the engagement slots 390′configured to receive the second spring tang 376′ may each define anangled surface 392′ extending radially inwardly from the outer wall 380while the engagement slots 388′ configured to receive the first springtang 372′ may also define an angled surface 394′ extending radiallyinwardly from the outer wall 380′.

It should be appreciated that the clutch assemblies 160, 160′ describedabove may provide certain advantages over conventional “slip clutches”that utilize a friction material to provide a friction/slip interfacewithin the clutch. Specifically, such conventional clutches aretypically subject to significant wear at the friction/slip interface asthe clutch is operated over time. As such, due to the wear, theseclutches must be periodically adjusted to maintain the required slippageforce at the friction/slip interface. However, the disclosed clutchassemblies 160, 160′ avoid such wear issues by utilizing clutch springs320, 322, 320′, 322′ to selectively engage/disengage the associatedclutch drive members 316, 318, 316′, 318′. Since the interface betweenthe clutch springs 320, 322, 320′, 322′ and the clutch drive members316, 318, 316′, 318′ is subject to no or minimal wear, the clutchassemblies 160, 160′ may be operated continuously over time withoutrequiring any adjustments.

It should also be appreciated that, in other embodiments, the disclosedclutch assemblies 160, 160′ may have any other suitable configurationthat allows the clutch assemblies 160, 160′ to function as describedherein. For instance, in one alternative embodiment, the first andsecond clutch springs 320, 322, 320′, 322′ may be formed integrally as asingle, unitary spring. Specifically, in such an embodiment, the firstand second spring tangs 372, 376, 372′, 376′ may be formed from asingle, continuous wire extending directly between the first and secondcoiled sections 370, 374, 370′, 374′, with the first coiled section 370,370′ being wrapped around the first clutch drive member 316, 316′ so asto form all or part of the first torque transfer member and the secondcoiled section 374, 374′ being wrapped around the second drive member318, 318′ so as to form all or part of the second torque transfermember.

In yet another embodiment, the clutch springs 320, 322, 320′, 322′ maybe provided in a different positional relationship relative to theclutch drive members 316, 318, 316′, 318′. For instance, in theembodiments shown in FIGS. 10-21, the clutch springs 320, 322, 320′,322′ are installed on the clutch drive members 316, 318, 316′, 318′ soas to engage the outer diameter of the spring support sections 334, 358,334′, 358′. However, in other embodiments, the clutch drive members 316,318, 316′, 318′ may be reconfigured to allow each clutch spring 320,322, 320′, 322′ to engage or otherwise have an interference fit with aninner diameter of a portion of its respective clutch drive member 316,318, 316′, 318′. For instance, the spring support section 334, 358,334′, 358′ of each clutch drive member 316, 318, 316′, 318′ may beformed as a sleeve or may otherwise define a pocket for receiving theassociated clutch spring 320, 322, 320′, 322′ such that the clutchspring 320, 322, 320′, 322′ engages the inner diameter of the sleeve orpocket. In such an embodiment, the interference fit between each clutchspring 320, 322, 320′, 322′ and the inner diameter of the associatedclutch drive member 316, 318, 316′, 318′ may determine the slippagetorque for the clutch assembly 160, 160′. Alternatively, a combinationof inner and outer interference fits may be provided within the clutchassembly 160, 160′. For example, one of the clutch springs 320, 322,320′, 322′ may be configured to form an interference fit with an outerdiameter of its respective clutch drive member 316, 318, 316′, 318′while the other clutch spring 320, 322, 320′, 322′ may be configured toform an interference fit with an inner diameter of its respective clutchdrive member 316, 318, 316′, 318′.

Referring now to FIGS. 22-25, several views of one illustrativeembodiment of a coupling assembly 132 suitable for use within thedisclosed shutter assembly 100 are illustrated in accordance withaspects of the present subject matter. It should be appreciated that thecoupling assembly 132 may, in one embodiment, illustrate aspects of thefirst coupling assembly 132A and/or the second coupling assembly 132Bdescribed above with reference to FIGS. 1-3.

As indicated above with reference to FIG. 3, each coupling assembly 132of the shutter assembly 100 may be configured to be driven by therespective drive shaft 150A, 150B extending within its associatedshutter panel 104A, 104B. Additionally, each coupling 132 may beconfigured to installed within or on its associated shutter panel 104A,104B so that the coupling assembly 132 engages a corresponding couplingassembly 132 installed within the adjacent shutter panel 104A, 104B atthe panel-to-panel interface 110 defines between the shutter panels104A, 104B. Thus, when engaged with each other, the coupling assemblies132 may be configured to transfer rotational motion or torque from thefirst drive shaft 150A to the second drive shaft 150B across the panelto panel interface 110.

As shown in FIGS. 22-24, each coupling assembly 132 includes a couplingbase 400 and a spring-loaded coupler 402 configured to be receivedwithin coupling base 400. In general, the coupling base 400 includes abase wall 404 and a cylindrical outer wall 406 extending outwardly fromthe base wall 404. In the embodiment of FIGS. 22-24, the outer wall 406defines a cylindrically-shaped open volume 408 (FIG. 24) for receivingthe coupler 402. Additionally, as shown in FIGS. 23 and 24, the couplingbase 400 includes a central projection 410 (FIG. 24) extending outwardlyfrom the base wall 404 that defines a shaft opening 412 (FIG. 23) forreceiving a corresponding drive shaft 150A, 150B of the drive system134. As particularly shown in FIG. 23, in one embodiment, the shaftopening may be keyed or otherwise configured (e.g., by including a“V-shaped” key 414) so that the drive shaft 150A, 150B engages thecoupling base 400 when the drive shaft 150A, 150B is received within theshaft opening 412. Thus, rotational motion or torque may be transferredfrom the drive shaft 150A, 150B to the coupling base 400 and vice versa.

Additionally, as shown in FIGS. 23-25, the coupler 402 includes an endwall 416 and a cylindrical outer wall 418 extending outwardly from theend wall 416. As shown in the illustrated embodiment, the outer wall 418of the coupler 402 includes a plurality of engagement flanges 420extending outwardly therefrom, with each flange 402 being configured tobe received within a corresponding slot or channel 422 of the couplingbase 400. Thus, when the coupler 402 is installed relative to thecoupling base 400, the coupling base 400 may engage the coupler 402 viathe interaction between the channels 422 and corresponding flanges 420,thereby allowing the coupler 402 to rotate together with both thecoupling base 400 and the associated drive shaft 150A, 150B.

The configuration of the channels 422 and the flanges 420 may also allowfor the coupler 402 to slide or move axially relative to the couplingbase 400, thereby permitting the coupler 402 to move towards and awayfrom the base wall 404 of the coupling base 400. For instance, as shownin FIGS. 23 and 24, the coupling assembly 132 includes a spring 424(e.g., a tapered spring) configured to be positioned between thecoupling base 400 and the coupler 402 (e.g., between the base wall 404of the coupling base 400 and the end wall 416 of the coupler 402) tobias the coupler 402 outwardly away from the base wall 404 of thecoupling base 404. However, by providing the axially extending channels422 and flanges 420, the coupler 402 may be moved axially towards thebase wall 404 of the coupling base 404 by pushing the coupler 402inwardly within the coupling base 400 in a manner that compresses thespring 424. In this regard, as shown in FIG. 25, the coupler 402 definesa central opening 426 through its end wall 416 that is configured toreceive the central projection 410 of the coupling base 400 as thecoupler 402 is moved axially relative to the coupling base 400. Itshould also be appreciated that the coupling base 400 also includes astop(s) 428 (FIG. 24) (e.g., at the open ends of the channels 422) tolimit the axial movement of the coupler 402 in the direction away fromthe base wall 404 of the coupling base 400.

Moreover, the coupler 402 also includes a plurality of axially extendingengagement ribs 430 projecting outwardly from its end wall 416. As shownin FIG. 25, in one embodiment, the engagement ribs 430 may be providedin an annular array around the central opening 426 of the coupler 402,with each rib 430 being circumferentially spaced apart from adjacentribs 430. For instance, in the illustrated embodiment, the coupler 402includes eight ribs 430 spaced apart equally around the annular array sothat an offset angle 432 of forty-five degrees is defined between thecircumferential centerlines of adjacent ribs 430. However, in otherembodiments, the coupler 402 may include more or less than eight ribs430, with the ribs 430 having any other suitable circumferentialspacing.

Additionally, as shown in FIG. 25, due to the circumferential spacing ofthe ribs 430, a circumferential gap 434 may be defined between each pairof adjacent ribs 430. In one embodiment, the circumferential width ordimension of each circumferential gap 434 may be selected so as to begreater than a corresponding circumferential width 436 of each rib 430.As such, when adjacent coupling assemblies 132 are positioned end-to-endat the panel-to-panel interface 110 defined between the shutter panels104A, 104B, the ribs 430 of each coupler 402 may be received within thecircumferential gaps 434 defined between the ribs 430 of the adjacentcoupler 402, thereby allowing the coupling assemblies 132 to engage eachother and transfer rotational motion or torque across the panel-to-panelinterface 110. Moreover, in one embodiment, the width or dimension ofeach circumferential gap 434 may be selected so as to be less than agiven radial dimension of each rib 430 (e.g., a radial height 438 (FIG.25) of each rib 430). Such dimensioning of the ribs 430 andcorresponding circumferential gaps 434 may ensure that the adjacentcoupling assemblies 132 engage each other properly when the shutterpanels 104A, 104B are moved to their closed position and may alsofacilitate engagement of the coupling assemblies 132 when suchassemblies 132 are initially misaligned.

It should be appreciated that, in the event that the couplers 402 ofadjacent coupling assemblies 132 are not properly aligned when theshutter panels 104A, 104B are moved to the closed position (e.g., theribs 430 of one coupler 402 are not aligned with the circumferentialgaps 434 of the adjacent coupler 402), subsequent rotation of one of thedrive shafts 150A, 150B (e.g. by the motor 140 or manually) may resultin the adjacent couplers 402 becoming aligned and engaging each other.For example, with the motor 140 of the shutter assembly 100 beingcoupled to the first drive shaft 150A, the motor 140 may rotate thefirst drive shaft 150A relative to the second drive shaft 150B until thecoupler 402 of the first coupling assembly 132A is properly aligned withthe coupler 402 of the second coupling assembly 132B, at which point thesprings 424 contained within each coupling assembly 132A, 132B may forcethe adjacent couplers 402 towards each other and into engagement toallow the rotation of the first drive shaft 150A to be transferred tothe second drive shaft 150B.

Referring now to FIGS. 26-29, several views of another illustrativeembodiment of a coupling assembly 132′ suitable for use within thedisclosed shutter assembly 100 are illustrated in accordance withaspects of the present subject matter. Specifically, FIGS. 26-29generally correspond to similar views of the coupling assembly 132′ asthose shown above for coupling assembly 132 (i.e., in FIGS. 22-25). Ingeneral, the coupling assembly 132′ shown in FIGS. 26-29 and itsassociated components are configured similar to the various componentsof the coupling assembly 132 described above. As such, the components orfeatures of the coupling assembly 132′ that are the same or similar tocorresponding components or features of the coupling assembly 132described above with reference to FIGS. 22-15 will be designated by thesame reference character with an apostrophe (′) added. Additionally,when a given component or feature of the coupling assembly 132′ isconfigured to generally perform the same function as the correspondingcomponent or feature of the coupling assembly 132 described above withreference to FIGS. 22-25, a less detailed description of suchcomponent/feature will be provided with reference to FIGS. 26-29 for thesake of brevity.

As shown in FIGS. 26-28, the coupling assembly 132′ includes a couplingbase 400′ and a spring-loaded coupler 402′ configured to be coupled tothe coupling base 400′. In general, the coupling base 400′ includes afirst base wall 404′, an opposed second base wall 405′, and acylindrical outer wall 406′ extending between the base walls 404′, 405′such that the coupling base 400′ forms a cylindrically-shaped component.Additionally, as shown in FIGS. 27 and 28, the coupling base 400′includes a central projection 410′ (FIG. 24′) extending outwardly fromthe second base wall 405′ that at least partially defines a shaftopening 412′ (FIG. 27) for receiving a corresponding drive shaft 150A,150B of the drive system 134. As particularly shown in FIG. 27, in oneembodiment, the shaft opening 412′ may be keyed or otherwise configured(e.g., by including a “V-shaped” key 414′) so that the drive shaft 150A,150B engages the coupling base 400′ when the drive shaft 150A, 150B isreceived within the shaft opening 412′.

Additionally, as shown in FIGS. 27-29, the coupler 402′ includes an endwall 416′ and a cylindrical outer wall 418′ extending outwardly from theend wall 416′ such that the outer wall 418′ defines acylindrically-shaped open volume 408′ (FIG. 27) for at least partiallyreceiving the coupling base 400′. As shown in the illustratedembodiment, the outer wall 418′ of the coupler 402′ defines a pluralityof engagement recesses 421′, 423′, with each recess 421′, 423′ beingconfigured to receive a corresponding feature 425′, 427′ of the couplingbase 400. For instance, as shown in FIGS. 28 and 29, a pair ofclosed-end recesses 421′ are defined in the outer wall 418′ that areconfigured to receive corresponding engagement tabs 425′ projectingradially outwardly from the second base wall 405′ of the coupling base400′. Similarly, a pair of open-end recesses 423′ are defined in theouter wall 418′ that are configured to receive corresponding engagementflanges 427′ projecting radially outwardly from the outer wall 406′ ofthe coupling base 400′. Thus, when the coupler 402′ is installedrelative to the coupling base 400′, the coupling base 400′ may engagethe coupler 402′ via the interaction between the recesses 421′, 423′ andcorresponding engagement features 425′, 427′, thereby allowing thecoupler 402′ to rotate together with both the coupling base 400′ and theassociated drive shaft 150A, 150B.

The configuration of the recesses 421′, 423′ and correspondingengagement features 425′, 427′ may also allow for the coupler 402′ toslide or move axially relative to the coupling base 400′, therebypermitting the end wall 416′ of the coupler 402′ to move towards andaway from the coupling base 400′. For instance, as shown in FIGS. 27 and28, the coupling assembly 132 includes a plurality of springs 424′configured to be positioned between the coupling base 400′ and thecoupler 402′ (e.g., between the first base wall 404′ of the couplingbase 400′ and the end wall 416′ of the coupler 402′) to bias the endwall 416′ of the coupler 402′ outwardly away from the coupling base404′. Additionally, the end wall 416′ of the coupler 402′ may be movedaxially towards the second base wall 405′ of the coupling base 400′ bypressing the components together in a manner that compresses the springs424′. In this regard, as shown in FIGS. 27 and 28, the coupler 402′defines a central opening 426′ through its end wall 416′ that isconfigured to receive the central projection 410′ of the coupling base400′ as the coupler 402′ is moved axially relative to the coupling base400′. It should also be appreciated that the engagement tabs 425′ of thecoupling base 400′ may be configured as stops that serve to limit theaxial movement of the coupler 402′ in the direction away from the secondbase wall 405′ of the coupling base 400′. For instance, the engagementtabs 425′ of the coupling base 400′ may contact the closed ends of therecesses 421′ to prevent further axial movement of the coupler 402′ awayfrom the second base wall 405′ of the coupling base 400′.

The coupling assembly 132′ may also include one or more features forretaining the springs 424′ in position between the coupling base 400′and the coupler 402′. For instance, as shown in FIG. 28, the couplingbase 400′ may include spring openings 428′ defined therein that extendinwardly from the second base wall 405′. Additionally, as shown in FIG.27, the coupler 402′ may include spring posts 431′ extending from itsend wall 416′ within the cylindrically-shaped open volume 408′ definedby the outer wall 418′ of the coupler 402′. In such an embodiment, wheninstalling the springs 424′ with the coupling assembly 132′, one end ofeach spring 424′ may be installed over a corresponding spring post 431′of the coupler 402′ while the opposed end of such spring 424′ may bereceived within a corresponding spring opening 429′ of the coupling base400′.

Moreover, the coupler 402′ also includes a plurality of axiallyextending engagement ribs 430′ projecting outwardly from its end wall416′. As shown in FIG. 29, in one embodiment, the engagement ribs 430′may be provided in an annular array around the central opening 426′ ofthe coupler 402′, with each rib 430′ being circumferentially spacedapart from adjacent ribs 430′. For instance, similar to the coupler 402described above, the coupler 402′ includes eight ribs 430′ spaced apartequally around the annular array so that an offset angle 432′ offorty-five degrees is defined between the circumferential centerlines ofadjacent ribs 430′. Additionally, as shown in FIG. 29, due to thecircumferential spacing of the ribs 430, a circumferential gap 434′ maybe defined between each pair of adjacent ribs 430′. In one embodiment,the circumferential width or dimension of each circumferential gap 434′may be selected so as to be greater than a corresponding circumferentialwidth 436′ of each rib 430′ to allow the ribs 430′ of one coupler 402′to be received within the circumferential gaps 434′ defined between theribs 430′ of an adjacent coupler 402′, thereby permitting a pair ofcoupling assemblies 132′ to engage each other and transfer rotationalmotion or torque across the panel-to-panel interface 110. Moreover, inone embodiment, the width or dimension of each circumferential gap 434′may be selected so as to be less than a given radial dimension of eachrib 430′ (e.g., a radial height 438′ (FIG. 29) of each rib 430′) toensure that the adjacent coupling assemblies 132′ engage each otherproperly when the shutter panels 104A, 104B are moved to their closedposition and to facilitate engagement of the coupling assemblies 132′when such assemblies 132′ are initially misaligned.

It should be appreciated that, in one embodiment, the coupling assembly132′ may include one or more features in addition to the shaft opening412′ to facilitate rotationally engaging the drive shaft 150A, 150B ofthe drive system 134. For instance, as particularly shown in FIGS. 27and 28, a set screw opening 441′ may be defined through a portion of thecoupling base 200 (e.g., through one of the flanges 427′) for receivinga set screw 443′. In such an embodiment, the set screw 443′ may bescrewed into the set screw opening 441′ and tightened into the driveshaft 150A, 150B to securely couple the coupling assembly 132′ to thedraft shaft 150A, 150B, thereby preventing or minimizing rotational lashor play between such components. Additionally, in such an embodiment, acorresponding groove or recess 445′ (FIG. 18) may be defined in thedrive shaft 150A, 150B for receiving the end of the set screw 443′,thereby providing a rotational locking or engagement feature between theset screw 443′ and the drive shaft 150A, 150B.

The assembled configuration and operation of one illustrative embodimentof the drive system 134 for the disclosed motorized shutter assembly 100will now be described with reference to FIGS. 30-33. Specifically, FIGS.30-33 illustrate several assembled views of one illustrative embodimentof various drive system components installed within the first shutterpanel 104A of the disclosed shutter assembly 100, such as the motor 140,the first drive shaft 150A, the first clutch assembly 160A, the firstdrive rack assembly 148A, one of the first driven rack assemblies 152A,and the first coupling assembly 132A. Additionally, FIG. 34 illustratesan assembled view of various drive system components installed withinboth the first shutter panel 104A and the second shutter panel 104B ofthe disclosed shutter assembly 100, particularly illustrating the drivesystem components positioned at or adjacent to the panel-to-panelinterface 110 defined between the shutter panels 104A, 104B. It shouldbe appreciated that, for purposes of illustration, the clutch assembliesshown in FIGS. 30-33 are illustrated as being configured in accordancewith the embodiment of the clutch assembly 160′ shown in FIGS. 16-21,the drive and driven rack assemblies shown in FIGS. 30-33 areillustrated as being configured in accordance with the embodiments ofthe rack assemblies 148′, 152′ shown in FIGS. 8 and 9 and FIGS. 6 and 7,respectively, and the coupling assemblies shown in FIGS. 30-33 areillustrated as being configured in accordance with the clutch assembly132′ shown in FIGS. 26-29. However, in other embodiments, suchcomponents may have any other suitable configuration consistent with thedisclosure provided herein.

As particularly shown in FIG. 30, in one embodiment, the first driveshaft 150A is configured to extend axially from a first shaft end 170 toa second shaft end 172, with the shaft 150A extending through both thefirst clutch assembly 160A and the first drive rack assembly 148Abetween its first and second ends 170, 172. In general, the first shaftend 170 of the drive shaft 150A may be configured to be coupled to themotor 140 to allow the motor 140 to drive the drive shaft 150A. Forinstance, as shown in FIG. 30, in one embodiment, the drive shaft 150Amay be directly coupled to an output shaft 174 of the motor 140 (e.g.,via a set screw 176). Alternatively, the drive shaft 150A may beindirectly coupled to the output shaft 174 of the motor 140, such as byproviding a separate shaft coupling between the output shaft 174 and thefirst shaft end 170 of the drive shaft 150A. Additionally, the secondshaft end 172 of the drive shaft 150A may be configured to be coupled tothe first coupling assembly 132A to allow the drive shaft 150A totransfer rotational motion or torque to the first coupling assembly132A. For instance, as shown in FIGS. 30 and 33, the second shaft end172 may be received within the shaft opening 412′ (FIG. 33) defined bythe coupling base 400′ of the first coupling assembly 132A.

As indicated above, the drive shaft 150A may be configured to engage thefirst clutch drive member 316′ of the first clutch assembly 160A as itextends through the clutch assembly 160A. However, the drive shaft 150Amay also be configured to pass freely through the second clutch drivemember 318′ of the first clutch assembly 160A. Moreover, as shown inFIG. 30, the second clutch drive member 318′ of the first clutchassembly 160A may be configured to extend outwardly from the clutchhousing 300′ to allow a portion of the second clutch drive member 318′to be received within the first drive rack assembly 148A. Specifically,as indicated above and as shown in FIG. 31, the splined section of theelongated drive portion 360′ of the second clutch drive member 318′ maybe configured to be received within the splined opening 248′ defined bythe rack gear 202′ of the first drive rack assembly 148A. As such, thesecond clutch drive member 318′ may be configured to drive the firstdrive rack assembly 148A.

When operating the disclosed drive system 134 via the motor 140, therotational motion or torque of the motor 140 may be transferred throughthe first drive shaft 150A to the first clutch drive member 316′. Sincethe torque required to rotationally drive the louvers 114 of eachshutter panel 104A, 104B is less than the slippage torque associatedclutch springs 320′, 322′, both springs 320′, 322′ may remain engagedwith their corresponding drive members 316′, 318′, thereby allowing therotational motion of the first clutch drive member 316′ to betransferred to the second clutch drive 318′ member via the connection orcoupling provided by the clutch springs 320′, 322′ and the associatedclutch sleeve 324′. Such transfer of torque between the first and secondclutch drive members 316′, 318′ may allow the second clutch drive member318′ to drive the rack gear 202′ of the first drive rack assembly 148A,resulting in relative linear translation of both the geared racks 204′,206′ (FIG. 31) of the first drive rack assembly 148A and the associateddrive bars 154, 156 (FIG. 31). As particularly shown in FIG. 31, sincethe drive bars 154, 156 are coupled to each of the first driven rackassemblies 152A of the drive system 134, the relative linear translationof the drive bars 154, 156 may be transferred to the geared racks 204′,206′ of each first driven rack assembly 152A, thereby causing the rackgears 202′ of each first driven rack assembly 152A to be rotated. Asindicated above, the rack gears 202′ of each first driven rack assembly152A may be coupled to a corresponding louver drive post 158A (FIG. 3)of one of the driven louvers 114A. Thus, rotation of the rack gears 202′of the first driven rack assemblies 152A may, in turn, drive the louverdrive posts 158A, thereby resulting in corresponding rotation of boththe driven louvers 114A and the non-driven louvers 114 of the firstshutter panel 104A (e.g., via the connection provided by the tie bars136). It should be appreciated that the motor 140 may be configured tobe rotated in one direction to cause the louvers 114 to rotate abouttheir longitudinal axes in a first direction, and in the oppositedirection to cause the louvers 114 to rotate about their longitudinalaxis in a second, opposed direction.

Similarly, rotation of the first drive shaft 150A via the motor 140 mayalso drive the first coupling assembly 132A via the connection providedbetween the second shaft end 172 of the drive shaft 150A and thecoupling base 400′ of the first coupling assembly 132A. As indicatedabove and as shown in FIG. 34, the first coupling assembly 132A may beconfigured to engage the second coupling assembly 132B of the secondshutter panel 104B at the panel-to-panel interface 110 defined betweenthe shutter panels 104A, 104B. Thus, torque from the motor 140 may betransferred from the first coupling assembly 132A to the second couplingassembly 132B across the panel-to-panel interface 110 to drive thevarious drive system components contained within the second shutterpanel 104B. For instance, as shown in FIG. 34, an end 180 of the seconddrive shaft 150B may be coupled to the second coupling assembly 132B. Assuch, torque transmitted across the panel-to-panel interface 110 maydrive the second drive shaft 150B, thereby allowing the drive shaft 150Bto drive the remainder of the related drive system components (e.g., thesecond clutch assembly 160B, the second drive rack assembly 148B, thesecond driven rack assemblies 152B and the corresponding louver driveposts 158B (FIG. 3)).

It should be appreciated that the first and second coupling assemblies132A, 132B may be configured to be retained within their associatedshutter panel 104A, 104B at the panel-to-panel interface using anysuitable means known in the art. For instance, as shown in FIGS. 32 and33, in one embodiment, a retainer ring 182 may be secured between eachcoupling assembly 132A, 132B and the associated shutter frame 112A, 112Bto maintain the relative positioning between such components. As shownin FIG. 33, the retainer ring 182 may, in one embodiment, be configuredto axially engage a portion of the end wall 416′ of the coupler 402′.

Additionally, when operating the disclosed drive system 134 manually,the user or operator may be allowed to grasp one of the louvers 114 ofthe first shutter panel 104A and rotate it about its longitudinal axis.Given the connection between the various louvers 114 of the firstshutter panel 104A (e.g., via the tie bar 136), all of the louvers 114may rotate simultaneously with one another, thereby causing therotational motion of the drive louvers 114A to serve as an input torqueto the rack gears 202′ of the first driven rack assemblies 152A. Suchrotation of the rack gears 202′ of the first driven rack assemblies 152Amay then cause relative linear translation of both the geared racks204′, 206′ of the first driven rack assemblies 152A and the associateddrive bars 154, 156. The relative linear translation of the drive bars154, 156 may, in turn, be transferred to the geared racks 204′, 206′ ofeach first drive rack assembly 148A, thereby causing the rack gear 202′of the first drive rack assembly 148A to be rotated and, thus, rotationof the second clutch drive member 318′ coupled to the rack gear 202′.Since the slippage torque for the clutch springs 320′, 322′ is less thanthe torque transmitted through the drive system 134 when manuallyrotating the louvers 114, the torque transmitted from the first driverack assembly 148A to the clutch assembly 160A may result in one of theclutch springs 320′, 322′ slipping, thereby decoupling the first clutchdrive member 316′ from the second drive member 318′. For instance, asindicated above, the clutch springs 320′, 322′ may be wound in opposeddirections. As such, when the louvers 114 are manually rotated in afirst direction, the increased torque transmitted through the clutchassembly 160A may result in the first clutch spring 320′ tighteningaround the outer spring support surface 342′ (FIG. 19) of the firstclutch drive member 316′ and the second clutch spring 322′ loosening orexpanding relative to the outer spring support surface 366′ (FIG. 20) ofthe second clutch drive member 318′, thereby disengaging the connectionbetween the first and second clutch drive members 316′, 318′ at thelocation of the interface between the second clutch spring 322′ and theadjacent outer spring support surface 366′ and preventing the torquetransmitted from the first drive rack assembly 148A from beingtransferred to the first clutch drive member 316′. Similarly, when thelouvers 114 are manually rotated in the opposite direction, theincreased torque transmitted through the clutch assembly 160A may resultin the second clutch spring 322′ tightening around the outer springsupport surface 366′ of the second clutch drive member 318′ and thefirst clutch spring 320′ loosening or expanding relative to the outerspring support surface 342′ of the first clutch drive member 316′,thereby disengaging the connection between the first and second clutchdrive members 316′, 318′ at the location of the interface between thefirst clutch spring 320′ and the adjacent outer spring support surface342′ and preventing the torque transmitted from the first drive rackassembly 148A from being transferred to the first clutch drive member316′.

It should be appreciated that the second clutch assembly 160B may beconfigured to operate the same as the first clutch assembly 160A.Specifically, when the louvers 114 of the second shutter panel 104B aremanually rotated, the increased torque transmitted through the seconddrive rack assembly 148B to the second clutch assembly 160B may resultin one of the clutch springs 320′, 322′ of the second clutch assembly160B slipping relative to its adjacent outer spring support surface342′, 366′, thereby disengaging or decoupling the first and secondclutch drive members 316′, 318′ of the second clutch assembly 160B fromeach other.

It should also be appreciated that, although the shutter assembly 100has generally been described herein as including two shutter panels104A, 104B, the disclosed drive system 134 may be utilized with shutterassemblies having any suitable number of shutter panels. For instance,FIG. 35 illustrates an embodiment of the disclosed shutter assembly 100in which the assembly 100 further includes a third shutter panel 104C.In such an embodiment, the drive system 134 may be configured the sameas that described above with the addition of further drive componentsfor driving the louvers 114 of the third shutter panel 104C. Forinstance, as shown in FIG. 35, the drive system 134 may include thirdand fourth coupling assemblies 132C, 132D positioned at thepanel-to-panel interface 110 defined between the second shutter panel104B and the third shutter panel 104C to allow rotational motion ortorque from the second drive shaft 150B to be transferred to a thirddrive shaft 150C extending within a shutter frame 112C of the thirdshutter panel 104C. Additionally, as shown in FIG. 35, the drive system134 may also include a third clutch assembly 160C coupled between thethird drive shaft 150C and a third louver drive assembly 146C configuredto drive the driven louvers 114C of the third shutter panel 104C.Similar to that described above, the third louver drive assembly 146Cmay, in one embodiment, be configured as a rack and pinion-type drivearrangement and may include a third drive rack assembly 148C engagedwith the third clutch assembly 160C and one or more third driven rackassemblies 152C coupled to the third drive rack assembly 148C via a pairof drive bars 157, with each third driven rack assembly 152C beingcoupled to a corresponding louver drive post 158C of each driven louver114C.

It should also be appreciated that, although the shutter panels 104A,104B have generally been described herein as including continuousvertical sections of louvers 114, the disclosed drive system 134 mayalso be utilized with shutter panels having divider rails. For instance,FIG. 36 illustrates an embodiment of the disclosed shutter assembly 100in which each shutter panel 104A, 104B includes a divider rail 115A,115B. Specifically, in the illustrated embodiment, the first shutterpanel 104A includes a first divider rail 115A, thereby dividing thefirst shutter panel 104A into an upper panel section 117A extendingvertically between the first divider rail 115A and the top rail 120 ofthe first shutter panel 104A and a lower panel section 119A extendingvertically between the first divider rail 115A and the bottom rail 122of the first shutter panel 104A. Similarly, the second shutter panel104B includes a second divider rail 115B, thereby dividing the secondshutter panel 104B into an upper panel section 117B extending verticallybetween the second divider rail 115B and the top rail 128 of the secondshutter panel 104B and a lower panel section 119B extending verticallybetween the second divider rail 115B and the bottom rail 130 of thesecond shutter panel 104B. In such an embodiment, the louvers 114contained within the lower panel sections 119A, 119B may be driven bythe various drive system components described above (e.g., the motor140, the first and second drive shafts 150A, 150B, the first and secondclutch assemblies 160A, 160B, and the various components of the firstand second louver drive assemblies 146A, 146B.

Additionally, the drive system 134 also includes various systemcomponents for driving the louvers 114 contained within the upper panelsections 117A, 117B. For instance, in one embodiment, the drive systemcomponents for the louvers 114 contained within the upper panel sections117A, 117B may be configured the same as or similar to the drive systemcomponents for the louvers 114 contained within the lower panel sections119A, 119B. Specifically, as shown in FIG. 36, a motor 140* installedwithin the top rail 120 of the first shutter panel 104A may be coupledto a first drive shaft 150A* extending within the top rail 120, whichis, in turn, coupled to a second drive shaft 150B* extending within thetop rail 128 of the second shutter panel 104B via first and secondcoupling assemblies 132A*, 132B* positioned at the panel-to-panelinterface 110. Additionally, the drive system 134 also includes firstand second clutch assemblies 160A*, 160B*, with the first clutchassembly 160A* being coupled between the first drive shaft 150A* and afirst louver drive assembly 146A* for the louvers 114 contained withinthe upper panel section 117A and the second clutch assembly 160B* beingcoupled between the second drive shaft 150B* and a second louver driveassembly 146B* for the louvers 114 contained within the upper panelsection 117B. In such an embodiment, the louver drive assemblies 146A*,146B* may be configured the same as or similar to the louver driveassemblies described above 146A, 146B, such as by including a drive rackassembly 148A*, 148B* and one or more driven rack assemblies 152A*,152B* coupled to the drive rack assembly 148A*, 148B* via a pair ofdrive bars 154*, 156*.

While the foregoing Detailed Description and drawings represent variousembodiments, it will be understood that various additions,modifications, and substitutions may be made therein without departingfrom the spirit and scope of the present subject matter. Each example isprovided by way of explanation without intent to limit the broadconcepts of the present subject matter. In particular, it will be clearto those skilled in the art that principles of the present disclosuremay be embodied in other forms, structures, arrangements, proportions,and with other elements, materials, and components, without departingfrom the spirit or essential characteristics thereof. For instance,features illustrated or described as part of one embodiment can be usedwith another embodiment to yield a still further embodiment. Thus, it isintended that the present subject matter covers such modifications andvariations as come within the scope of the appended claims and theirequivalents. One skilled in the art will appreciate that the disclosuremay be used with many modifications of structure, arrangement,proportions, materials, and components and otherwise, used in thepractice of the disclosure, which are particularly adapted to specificenvironments and operative requirements without departing from theprinciples of the present subject matter. For example, elements shown asintegrally formed may be constructed of multiple parts or elements shownas multiple parts may be integrally formed, the operation of elementsmay be reversed or otherwise varied, the size or dimensions of theelements may be varied. The presently disclosed embodiments aretherefore to be considered in all respects as illustrative and notrestrictive, the scope of the present subject matter being indicated bythe appended claims, and not limited to the foregoing description.

In the foregoing Detailed Description, it will be appreciated that thephrases “at least one”, “one or more”, and “and/or”, as used herein, areopen-ended expressions that are both conjunctive and disjunctive inoperation. The term “a” or “an” element, as used herein, refers to oneor more of that element. As such, the terms “a” (or “an”), “one or more”and “at least one” can be used interchangeably herein. All directionalreferences (e.g., proximal, distal, upper, lower, upward, downward,left, right, lateral, longitudinal, front, rear, top, bottom, above,below, vertical, horizontal, cross-wise, radial, axial, clockwise,counterclockwise, and/or the like) are only used for identificationpurposes to aid the reader's understanding of the present subjectmatter, and/or serve to distinguish regions of the associated elementsfrom one another, and do not limit the associated element, particularlyas to the position, orientation, or use of the present subject matter.Connection references (e.g., attached, coupled, connected, joined,secured, mounted and/or the like) are to be construed broadly and mayinclude intermediate members between a collection of elements andrelative movement between elements unless otherwise indicated. As such,connection references do not necessarily infer that two elements aredirectly connected and in fixed relation to each other. Identificationreferences (e.g., primary, secondary, first, second, third, fourth,etc.) are not intended to connote importance or priority, but are usedto distinguish one feature from another.

All apparatuses and methods disclosed herein are examples of apparatusesand/or methods implemented in accordance with one or more principles ofthe present subject matter. These examples are not the only way toimplement these principles but are merely examples. Thus, references toelements or structures or features in the drawings must be appreciatedas references to examples of embodiments of the present subject matter,and should not be understood as limiting the disclosure to the specificelements, structures, or features illustrated. Other examples of mannersof implementing the disclosed principles will occur to a person ofordinary skill in the art upon reading this disclosure.

This written description uses examples to disclose the present subjectmatter, including the best mode, and also to enable any person skilledin the art to practice the present subject matter, including making andusing any devices or systems and performing any incorporated methods.The patentable scope of the present subject matter is defined by theclaims, and may include other examples that occur to those skilled inthe art. Such other examples are intended to be within the scope of theclaims if they include structural elements that do not differ from theliteral language of the claims, or if they include equivalent structuralelements with insubstantial differences from the literal languages ofthe claims.

The following claims are hereby incorporated into this DetailedDescription by this reference, with each claim standing on its own as aseparate embodiment of the present disclosure. In the claims, the term“comprises/comprising” does not exclude the presence of other elementsor steps. Furthermore, although individually listed, a plurality ofmeans, elements or method steps may be implemented by, e.g., a singleunit or processor. Additionally, although individual features may beincluded in different claims, these may possibly advantageously becombined, and the inclusion in different claims does not imply that acombination of features is not feasible and/or advantageous. Inaddition, singular references do not exclude a plurality. The terms “a”,“an”, “first”, “second”, etc., do not preclude a plurality. Referencesigns in the claims are provided merely as a clarifying example andshall not be construed as limiting the scope of the claims in any way.

What is claimed is:
 1. A shutter assembly, comprising: a shutter frame;a plurality of louvers supported by said shutter frame; a louver driveassembly positioned within said shutter frame, said louver driveassembly rotationally coupled to at least one driven louver of saidplurality of louvers; a motor positioned within said shutter frame, saidmotor being configured to rotationally drive a drive shaft extendingwithin said shutter frame; and a clutch assembly rotationally coupledbetween said drive shaft and said louver drive assembly, said clutchassembly including a first clutch drive member, a second clutch drivemember, and first and second torque transfer members coupled to eachother to provide a rotational coupling between said first and secondclutch drive members, said first torque transfer member configured to beselectively engaged with said first clutch drive member and said secondtorque transfer member configured to be selectively engaged with saidsecond clutch drive member; wherein, when a torque transmitted throughsaid clutch assembly exceeds a torque threshold, one of said firsttorque transfer member or said second torque transfer member isconfigured to disengage from a respective clutch drive member of saidfirst and second clutch drive members to decouple said first clutchdrive member from said second clutch drive member.
 2. The shutterassembly of claim 1, wherein when the torque transmitted through saidclutch assembly is less than the torque threshold, said first and secondtorque transfer members are engaged with said first and second clutchdrive members, respectively, to allow the torque to be transmittedbetween said first and second clutch drive members.
 3. The shutterassembly of claim 2, wherein a minimum torque required to rotationallydrive said plurality of louvers is less than the torque threshold suchthat the torque is transmitted between said first and second clutchdrive members when said motor is being operated to rotationally drivesaid louver drive assembly.
 4. The shutter assembly of claim 1, whereinthe torque transmitted through said clutch assembly exceeds the torquethreshold when said plurality of louvers are being manually rotated. 5.The shutter assembly of claim 1, wherein said first torque transfermember comprises a first clutch spring, and said second torque transfermember comprises a second clutch spring.
 6. The shutter assembly ofclaim 5, wherein: said first clutch spring is configured to beselectively engaged with a first spring support surface of said firstclutch drive member; and said second clutch spring is configured to beselectively engaged with a second spring support surface of said secondclutch drive member.
 7. The shutter assembly of claim 6, wherein, whenthe torque transmitted through said clutch assembly exceeds the torquethreshold: said first clutch spring is configured to tighten around saidfirst spring support surface and said second clutch spring is configuredto loosen relative to said second spring support surface when the torqueis transmitted through said clutch assembly in a first direction toallow said second clutch spring to slip relative to said second clutchdrive member; and said first clutch spring is configured to loosenrelative to said first spring support surface and said second clutchspring is configured to tighten around said second spring supportsurface when the torque is transmitted through said clutch assembly inan opposite, second direction to allow said first clutch spring to sliprelative to said first clutch drive member.
 8. The shutter assembly ofclaim 7, wherein the torque threshold comprises a torque value at whichsaid first and second clutch springs are configured to slip relativesaid first and second spring support surfaces.
 9. The shutter assemblyof claim 5, wherein said first and second clutch springs are coupled toeach other via a clutch sleeve such that said first and second clutchsprings and said clutch sleeve collectively form said rotationalcoupling between said first and second clutch drive members.
 10. Theshutter assembly of claim 1, wherein said louver drive assemblycomprises a drive rack assembly rotationally engaged with said clutchassembly and at least one driven rack assembly rotationally engaged witha louver drive post associated with the at least one driven louver. 11.The shutter assembly of claim 1, wherein: said shutter frame correspondsto a first shutter frame of a first shutter panel of said shutterassembly and said drive shaft corresponds to a first drive shaft of saidfirst shutter panel; said shutter assembly further comprises a secondshutter panel including a second shutter frame configured to extendadjacent to said first shutter frame at a panel-to-panel interfacedefined between said first and second shutter panels; said shutterassembly further comprises a first coupling assembly coupled to an endof said first drive shaft, and a second coupling assembly coupled to anend of said second drive shaft; and said first and second couplingassemblies are configured to engage each other at the panel-to-panelinterface such that rotational motion of said first drive shaft istransferred to said second drive shaft across the panel-to-panelinterface.
 12. A clutch assembly for use within a motorized shutter, themotorized shutter including a motor configured to rotationally drive adrive shaft and a louver drive assembly rotationally coupled to aplurality of louvers of the motorized shutter, the clutch assemblycomprising: a clutch housing; a first clutch drive member configured torotationally engage the drive shaft; a second clutch drive memberconfigured to rotationally engage a component of the louver driveassembly; a first torque transfer member configured to be selectivelyengaged with said first clutch drive member; a second torque transfermember configured to be selectively engaged with said second clutchdrive member, said first and second torque transfer members beingcoupled to each other to provide a rotational coupling between saidfirst and second clutch drive members; wherein, when a torquetransmitted through said clutch assembly exceeds a torque threshold, oneof said first torque transfer member or said second torque transfermember is configured to rotationally disengage from a respective clutchdrive member of said first and second clutch drive members to decouplesaid first clutch drive member from said second clutch drive member. 13.The clutch assembly of claim 12, wherein, when the torque transmittedthrough said clutch assembly is less than the torque threshold, saidfirst and second torque transfer members are engaged with said first andsecond clutch drive members, respectively, to allow the torque to betransmitted between said first and second clutch drive members.
 14. Theclutch assembly of claim 12, wherein said first torque transfer membercomprises a first clutch spring and said second torque transfer membercomprises a second clutch spring.
 15. The clutch assembly of claim 14,wherein the torque threshold corresponds to a slippage torque associatedwith the first and second clutch springs.
 16. The clutch assembly ofclaim 12, wherein: said first clutch drive member is configured to be atleast partially received within said clutch housing; and said secondclutch drive member is configured to be at least partially receivedwithin said clutch housing.
 17. A shutter assembly, comprising: a firstshutter panel including a first shutter frame, said first shutter panelfurther including a first drive shaft supported relative to said firstshutter frame; a second shutter panel including a second shutter frameconfigured to extend adjacent to said first shutter frame at apanel-to-panel interface defined between said first and second shutterpanels, said second shutter panel further including a second drive shaftsupported relative to said second shutter frame and being axiallyaligned with said first drive shaft; a motor rotatably coupled to saidfirst drive shaft; a first coupling assembly coupled to an end of saidfirst drive shaft; and a second coupling assembly coupled to an end ofsaid second drive shaft; wherein: said first coupling assembly includesa plurality of circumferentially spaced first engagement ribs extendingaxially towards said second coupling assembly at the panel-to-panelinterface; said second coupling assembly includes a plurality ofcircumferentially spaced second circumferentially spaced engagement ribsextending axially towards said first coupling assembly at thepanel-to-panel interface; and said first engagement ribs of said firstcoupling assembly are configured to rotationally engage said secondengagement ribs of said second coupling assembly at the panel-to-panelinterface such that rotational motion of said first drive shaft istransferred to said second drive shaft across the panel-to-panelinterface.
 18. The shutter assembly of claim 17, wherein said firstengagement ribs are spaced apart circumferentially in an annular arraysuch that a circumferential gap is defined between each adjacent pair ofsaid first engagement ribs.
 19. The shutter assembly of claim 18,wherein: each of said second engagement ribs defines a circumferentialwidth; and said circumferential width is less than a circumferentialwidth of said circumferential gap defined between each said adjacentpair of said first engagement ribs.
 20. The shutter assembly of claim17, wherein: said first engagement ribs are spaced apartcircumferentially in a first annular array such that a circumferentialgap is defined between each adjacent pair of said first engagement ribs;said second engagement ribs are spaced apart circumferentially in asecond annular array such that each second engagement rib is receivedwithin the circumferential gap defined between a respective adjacentpair of second first engagement ribs when said first and second couplingassemblies are rotationally engaged with each other.